NC programming increases output by 48%

Major Indian automotive manufacturer reports that an NC programming system is realising average savings of 15% in production time and up to 30% on processes such as drilling and boring.

Preferred supplier to major automotive companies worldwide, Rane (Madras) - RML- reported output had increased in some cases by as much as 48% per shift since it had EdgeCAM's system for NC part programming installed.

RML manufactures manual steering and suspension systems for cars, utility and commercial vehicles and tractors, which represented around 27% of group sales for the year 2006-2007.

One of the first commercial users of EdgeCAM in India, the company is realising major benefits in terms of improved cycle times and reduced prove out times since installing the software in 2006.

President of RML, Mr Parthasarathy, said: "Globalisation was starting to make an impact on our business.

We knew we had to utilise our existing capacity more efficiently, replace obsolete equipment and bring our processes more in line with the developing technology.

This included converting machine control from hydraulic to CNC and then, around 18 months ago, we started talking to EdgeCAM about its advanced CNC offline programming system".

RML spoke to several CAM suppliers before investing in the EdgeCAM system.

Working with EdgeCAM's Master Reseller for India, Adroitec Information Systems, the simulated cycle times were compared to the current ones and applied to various components.

Since replacing manual processes with CNC machinery, RML has seen a dramatic improvement in productivity and optimisation of its process through sequencing.

It reported savings of 15% on average in production time and up to 30% on processes such as drilling and boring.

Senior manager, manufacturing engineering at RML, Mr Prabhu, said: "It is important for us to constantly look at ways to quickly find the best solution for all of our processes, whether it is boring, cutting or drilling.

EdgeCAM has enabled us to achieve this, especially with the simulation facility, which saves us much time and expense and we plan to extend its use to other Rane sites".

He gave an example of productivity improvement using a multiple thread milling cutter.

The tool holder now provides five thread milling inserts instead of one, with the result that feed rate has increased from 700mm/min to 1500mm/min and spindle speed from 1500 rev/min to 2000 rev/min, while cutting time has been reduced by 7.2%.

"It is often difficult to introduce new procedures into production lines without holding things up," said Prabhu.

"With EdgeCAM we can simulate new ideas offline and prove out processes and different tools before we actually start machining virtually eliminating downtime.

We are then in a position to make educated decisions on when to introduce the new methods with minimum disruption".

EdgeCAM software has also been instrumental in the implementation of lean manufacturing techniques to improve performance across the factory, said EdgeCAM to manufacturingtalk.com.

Using the Job Manager function, the company is able to track operational sequences, prioritise jobs and balance each production line to achieve the maximum output.

"The overall effect of implementing EdgeCAM has surprised and pleased us," said Parthasarathy.

"In improving productivity output has increased in some cases by as much as 48% per shift the whole workforce is more motivated, manifesting an attitude that if you aim high you can achieve so much more".

Prabhu concluded: "The follow up has been fantastic wecouldn't ask for better support.

The project would not have been a success without it and since installation we have forged a strong and mutually beneficial business relationship with both Adroitec and EdgeCAM." He added: "The benefits were evident almost immediately and all the signs point to a payback within a period of just six months.

With our capabilities for independent product design and testing/validation, we are now a preferred system solution supplier to many domestic OEMs.

EdgeCAM has been highly instrumental in allowing us to achieve this".

* About EdgeCAM - EdgeCAM, a market leading computer aided manufacturing (CAM) system for NC part programming, offers a complete solution for milling, turning and mill/turn programming with unparalleled ease of use and sophisticated toolpath generation.

EdgeCAM is a principal brand of the Planit group recently ranked by CIMdata as the world's fastest growing CAM vendor, with most industrial users.

Planit is a global supplier of design and manufacturing software for the engineering, woodworking and stone industries.

The company provides its customers with products and services that enable them to improve the productivity of their machine tools, shorten design and manufacturing time, optimise material usage and deliver high quality goods and services to their customers.

Planit's solutions are best-in-class within their respective markets and are integral to the success of thousands of companies of every size around the globe.

* About RML - a principal company within the India-based Rane Group, Rane (Madras) Limited started out in 1960, supplying steering linkages to OEMs.

Today, the company manufactures steering and suspension systems for all sectors of the automotive industry.

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