Robotic Automation Reduces 40-Minute Part Production to Less Than 5 Minutes

Rusty documented every step of the existing manufacturing process from raw materials, through machining, inspection and preparation for shipping. “I decided to take the approach that everything we were currently doing to make these parts was wrong,” Rusty said. “This helped me look at the job with fresh eyes. Instead of simply trying to improve the process we already had, we rethought our entire approach to see how we could make these parts much more efficiently.”

The existing process began with receipt of bar stock that Northeast Tool would saw to size, load into the first machine tool to rough, turn one end and then set aside for batching. When a batch of parts was ready, each part would be individually loaded into additional machines for further processing, which included a polishing machine to achieve the required surface finish. Because of all of the handling in and out of machines, the parts often had to be re-polished to meet specifications.

What Rusty discovered was that each part traveled the equivalent of one mile throughout his facility from start to finish. The entire process required three CNC lathes, two milling operations, polishing, washing and inspections after each operation. Throughout this journey, the part was touched by more than 15 people over two and one-half shifts. These touches included sawing and stacking bar stock on pallets, machining, counting, batching, washing, inspecting and shipping. Recognizing that every touch adds cost to a part, Rusty knew he needed a less hands-on process.

A Turnkey Solution

Rusty began talking to suppliers to identify a company that had the capability to combine machining, inspection and automation. “I wanted a system that would integrate everything from raw materials to finished parts and could be attended by a single machine operator,” he said.

Not only is this a huge time savings, it also frees up considerable floor space that was occupied by the additional 14 people, tools and working space the former system required. “I then had the ability to add more machines to expand our capacity and repurpose our people to other jobs,” Rusty said.

An end-of-arm three-jaw O.D. gripper system grips the workpiece on the outside shank diameter for loading and unloading the lathes’ as well as placing and removing parts for post-process inspection on a Coordinate Measuring Machine (CMM).

All programs for the 17 part numbers reside in the machine tool and are called up by the automation system based on the next part to be processed. In operation, a part is located by the robot using the vision system to identify the 2D bar code, then loaded into the first machine tool that performs rough machining. The robot unloads the workpiece from the first machine and loads it into the second Okuma lathe where the front side is machined. The third lathe performs milling and second turning operations. Between operations, the robot flips parts as necessary based on the part program.

Post machining, the robot unloads the part from the third lathe and places it on a coordinate measuring machine for inspection.