Product category:
Horizontal machining centres (HMC)
News Release from: Heller Machine Tools | Subject: MCH 250 horizontal machining centres
Edited by the Manufacturingtalk Editorial
Team on 17 January 2007
HMCs reduce cylinder head cycle times by
60%
Two fast, versatile horizontal machining centres have reduced machining cycle times on diesel engine cylinder heads by some 60% and lowered production inspection requirements.
To continue manufacturing cylinder heads at its own facility, Perkins Stafford, UK, has again proved itself 'simply the best' and is installing two Heller MCH 250 horizontal machining centres alongside the Heller three machine con-rod cell Perkins Stafford - which last year achieved a 360% increase in productivity - succeeded in keeping work within its plant by combining intelligent and detailed cost justification with imaginative production process planning
This article was originally published on Manufacturingtalk on 27 Feb 2002 at 8.00am (UK)
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The plant manufactures the 4000 series diesel and gas engines, undertaking all the machining and assembly on the one site.
A routine business-risk analysis, it identified the existing FMS system for the cylinder heads as a 'concern' because of the age of the machines.
Six Sigma black belt, Chris Reads, said: "The machines were elderly and an analysis of machine performance indicated that whilst we were achieving the accuracy required, downtime and long term wear were becoming an issue so we needed to reconsider the manufacturing process.
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We had the option of refurbishing the machines, outsourcing, or installing a new manufacturing cell." Refurbishing the machines would only be a short-term option because although Perkins could bring the machines back to factory spec their remaining useful life would still be in doubt, the technology would be out-dated and the investment would be 'significant'.
The initial costing exercise on the remaining two options showed "Very subtle differences," Reads said.
"To attain an exact costs picture it was crucial to consider the fine detail and not 'broad brush' the overall costs because it is the fine details which are crucial to ensure the correct decision for the business." The more detailed cost justification, which took into account non-quantifiable benefits such as retaining control of quality, delivery to the assembly area, the development of a leaner manufacturing environment, and future manufacturing versatility, indicated a marked cost difference.
Apparent that manufacturing in-house was the most cost-effective route, Perkins selected a Heller cell from the three possible manufacturing processes it had identified.
Senior manufacturing engineer Mark Johnson, who headed the Six Sigma Green Belt team in charge of the project, said: "We selected Heller to be our partner again partly because by using two Heller machines we could reduce cycle time by almost 60%.
With 85% efficiency on the machines, which we knew from experience we could achieve on the Hellers, we could meet the production requirement within a standard five-day week.
Knowing the exceptional accuracy and repeatability of the Hellers, we also anticipate reducing inspection to only one head in ten, giving a much enhanced productivity." He added: "We also wanted to tap into Heller's experience of manufacturing cylinder heads.
Although we know a very great deal about manufacturing our cylinder heads, Heller has a wider and more profound understanding of cylinder head manufacturing processes built on a broad automotive customer base.
We wanted to use that experience to give us the most efficient and powerful manufacturing process." Johnson continued: "Even more importantly, we have experience of Heller's commitment and ability to support us.
In creating the three MCH250 con rod cell, we have developed a close working partnership with Heller and can work with their engineers as if they were our own." Installing Hellers for the cylinder head cell gave Perkins a further, much sought, advantage in that it provides a common operating platform, giving a much greater manufacturing flexibility.
For instance, although the standard five-port hydraulic system was sufficient for the cylinder head line, Perkins have opted for the 12-port system to match that on the con rod line, allowing fixtures to be moved from one cell to the other easily should it ever become necessary.
Johnson said: "It is also good for the operators.
Once the cell is installed operators will have flexibility in where they work because they will all be capable of working either in the con-rod or the cylinder head line.
It gives them greater ownership of their working life, and gives us enhanced performance." Prior to installing the Hellers, Perkins laid new, isolated foundations and removed all the overhead steel work and services to give more light in the area and an improved working ambience, a priority in all the work Perkins has undertaken during the last two years.
Once the initial plan for the cell had been created, the operators were involved in the detailed planning so that, for instance, the positioning and orientation of equipment such as the wash machine and the tool cabinet are strategically located.
Working with Heller engineers and using state-of-the-art simulation software the process was fine tuned and confirmed prior to affirmation of the final layout.
Johnson said: "Perkins always takes the most cost effective route using the Six Sigma Analysis so the final decision is based entirely on facts not feel.
We have shown that the way to realize cost effective manufacture is through investment rather than outsourcing.
From the outset we proved it was more cost effective to manufacture in house because we would have tighter control of the manufacturing and greater versatility to handle whatever the future brings." Johnson concluded: "We undertook the 'make or buy' analysis prior to installing the Heller cell for machining the con-rods, and that has now proved beyond any shadow of doubt that investment in the Stafford facility was the most cost effective and efficient option.
By working with Heller on this project, we have again demonstrated that manufacturing in the UK can be competitive on price, quality and delivery." * About the MCH and MCi horizontal machining centres - the MCH 250 is a fast, versatile machine developed primarily for higher volumes, typically the automotive industry.
The MCH 250 operates as a stand-alone machine and can be used equally well with overhead transfer, conventional FMS or linear linkage systems.
It provides easy access to all components, and has complete coolant and swarf management systems.
It benefits from the popular Siemens 840 D controller, giving assured optimal machine operation.
A Fanuc controller is offered as an option.
The chain magazine has been designed to provide extremely short tool-to-tool times because of its high travel rate.
Tools with SK50 and HSK100A toolholders are accepted in its 100 pocket chain magazine or in a 400 place rack type magazine.
Rapid traverse is 50,000mm/min as standard with 60,000mm/min as an option.
Acceleration is 4mm/s2 with 7mm/s2 as an option.
Chip to chip time is 3.8s to VDI. Request a free brochure from Heller Machine Tools ...
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