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How Automation Boosts Output in High-Mix Environments

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Machine shops of almost any size and production mix can automate machining operations. The key is selecting the right technology to fit the need and working with a reliable supplier to deliver planned performance. The result will be more opportunities for your shop to increase capacity, revenue, and profit.

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If you’re a job shop or other high-mix manufacturer you may not assume that automation is the right solution for you. But there are a variety of automation solutions that can be applied in high-mix applications and that can be tailored to your specific needs. They can dramatically reduce production and labor costs, achieve fast ROIs, and actually be simpler to manage than manual machine tending. The right solution will increase capacity while decreasing cost.

Machining automation can be as simple as adding a standard “bolt-on” multi-pallet system to a single machine. Easy and quick to implement, a pallet changer will deliver high efficiency for small lots, dramatically improve spindle utilization, and enable some degree of unattended machining. Or it can be an engineered cell for fully unattended production for medium to higher volume applications. And there are plenty of options in between. For job shops, the key is finding the right level of automation to serve your needs and that can become productive in a short period of time. Suppliers like Methods Machine Tools can help.

The Plus E automation system turns a FANUC RoboDrill into a mid-to-high volume center for unattended machining. The Plus E adds just 30 inches of width to the RoboDrill’s existing footprint, making the complete solution well suited for even small shops looking to scale up production.

 

Finding the Shop Automation Right Solution

How much automation do you need? “We have to ask a lot of questions,” says Bernie Otto, Methods Machine Tools’ Director of Technical Support. “High-mix/low-volume setups with longer cycle times might opt for an automatic pallet changer to process various parts without manual intervention, while a low-mix/high-volume shop would be more likely to integrate a robot to remove parts and insert stock into the machine,” he says.

Automation cells can open a world of options for any business. Cells themselves can be paired with different machine configurations and setups to maximize floor space. Meanwhile, parts can be loaded/unloaded from systems such as carousels, vises, trays, rotary stockers, multi-drawer systems, and in/outfeed conveyors.

Turn-Assist 200i and Turn-Assist 270i are semi-collaborative automation systems dedicated to CNC lathe automation for Nakamura-Tome machines. Turn-Assist is designed to be implemented and run by operators of any skill level. With its simple HMI and standard IP interface, shops using Turn-Assist can successfully change over from one part to another within minutes. 
 
 

Key Factors to Consider in Evaluating Automation

To get a better handle on how automation might help your machine shop, it’s helpful to keep these key factors in mind:

  • REALIZE FAST ROI – The right automation solution should provide a fast return on investment. You can drastically reduce load/unload times, labor costs, internal setup times, and scrap, all while reclaiming more hours of daily production. The return on investment should normally be less than 18 months, and sometimes it can be under a year.
     
  • FIND A GOOD PARTNER – Do your research, find an experienced automation integrator and review your options. There is no one-size-fits-all solution, so partner with a company that can identify your capabilities and needs to give you the best solution possible. Equipment providers who also offer automation services will provide a single source of contact and responsibility.
     
  • GET UP AND RUNNING QUICKLY – You can automate nearly any aspect of your shop, no matter what market you serve or the size of your operation. Automatic pallet changers can be easily integrated into any setup in a short period of time. Engineered cells will take more time, but the installation can often be done in a week or two.
     
  • IT’S EASIER THAN YOU THINK – Integration and programming of many automation solutions are straightforward. Machine shops can manufacture custom work handling tooling to fit their needs, and experienced integrators will work with shops to implement solutions quickly. More advanced automation specialists can help analyze your parts and deliver optimized solutions ranging from manufacturability assessments to part program optimization to throughput requirements, and then deliver a full turnkey solution.
The Methods Plus-K automation system combines a medium bed FANUC RoboDrill with 60 pallets, 44 additional tools (64 total) and a full five-axis table.
 
 

Let Methods Machine Tools Help

Methods Machine Tools has been working with shops for years to design the right combination of machine, automation, and tooling to deliver the throughput shops need to machine high-quality parts with maximum efficiency. With expert help you can get the capabilities you need without having to go through extensive trial and error or training processes. Job shops need solutions that work right out of the box, and Methods can help them get there.

Please visit the website for more information on Methods Machine Tools Automation platforms and services.

Methods Machine Tools automation services