Product category:
Control systems, DROs, etc, for machine tools
News Release from: Yamazaki Mazak UK | Subject: Mazak Cyber Production Centre
Edited by the Manufacturingtalk Editorial
Team on 25 April 2003
Manchine tool management extends to
China
One of the UK's first users of the Mazak Cyber Production Centre factory management concept is now to use the system to monitor machine tools at its new manufacturing operations in China.
One of the UK's first users of the Mazak Cyber Production Centre (CPC) factory management concept is now extending its use of the system to monitor machine tools at its new manufacturing operations in China Bishops Stortford based Urbanhurst has over 30 years specialising in the machining of automotive engine blocks, heads, power trains and other ancillary automotive equipment
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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The company - which specialises in lower volume, higher value components - has a major investment in Mazak machine tools, operating some 15 machining centres in total with the most recent additions being two Variaxis 5 axis double column 630-5X's and a PFH 5800 high speed horizontal machining centre.
With an inventory of around 1500 spindle tools, mostly Sandvik Coromant Varilock and Capto designs, in addition to some special tooling, three years ago Urbanhurst recognised that to achieve maximum efficiency of tool usage and production scheduling across its machining centres the need for an integrated production management system was becoming vital.
As such, it invested in the Mazak CPC software and currently operates the Cyber machine monitor and Cyber tool management modules.
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Having recently introduced one of the world's most innovative ranges of new generation machine tools Yamazaki Mazak will be featuring two of its 'e' models at the MACH 2002 exhibition.
A third module - Cyber scheduler - will come on-line in the summer of 2003.
Importantly, the scope of the CPC monitoring is shortly to be greatly expanded when four machines are shipped to China.
Urbanhurst has entered into a strategic and technological relationship with Asimco, the largest independent diversified manufacturer in China.
A new factory, primarily for the manufacture of engine components including spare parts for Caterpillar, is being established in Lang Fang, south west of Beijing in which the four Mazak machines will be re-located.
Before leaving the UK the Mazak machine tools all have been fitted with Mazak Mazatrol CPC hubs with the aim of interrogating and monitoring the machining operations from Bishops Stortford.
"Primarily we work on relatively small batches of high value production and prototype work," explains Terry Clarke, engineering manager at the plant.
"That philosophy in itself presents problems because we operate in a rapid response environment and the need for tight and precise scheduling is paramount.
"An average job going through our plant will use about 60 tools," he explains.
"Because of the size of the inventory and its diversity, we set out to find a cost effective method of maximising performance, streamlining the production operation and reducing metal cutting times.
An important factor was the ability to retro-fit the system to some of the older machines and in that sense the Mazak CPC has more than met our expectations." There are four elements to Mazak CPC, all of which are totally integrated.
The modules comprise Mazak CAMWARE, Cyber Scheduler, Cyber Tool Management and Cyber Machine Monitor.
All are inter-linked and directly manage the CNC machine tools at the very heart of the machine shop.
Mazak claims its CPC is the most powerful machining focused production management system available in the world.
The Cyber Tool Management is the key to optimising cutting time and minimising tooling costs whilst maintaining high quality machining.
This provides on-line tool status and tool life monitoring functions on Mazatrol equipped Mazak machines anywhere in the network.
The introduction of a newly developed Tool ID System eliminates human error and minimises job set-up times while providing optimum tool condition to maintain high cutting accuracy and efficiency.
Every toolholder in the plant has a chip in the pull stud.
This permits real time tool monitor and tracking throughout the plant - both in the machine tool pockets and storage rack - and provides details of insert wear and location errors.
The outcome ensures that the correct tool is in the right place at the right time, optimising uptime and simplifying what can be a time consuming and arduous task when undertaken manually.
The Cyber Machine Monitor provides real time machine monitoring, comprehensive machine utilisation reports and alarm history analysis which are essential to improve production efficiency and preventative maintenance.
In un-manned operations instant alarm notification, for example to a mobile telephone (via SMS), will minimise machine downtime.
When it becomes active at Urbanhurst, the Cyber Scheduler will play a pivotal role within CPC by linking the organisation's two 'upstream' Mazak CAMWARE suites and MRP, together with 'down stream' machining instruction, programme transfer, tool/fixture information and shop floor data collection.
This comprehensive scheduler provides all the information required for production management and shop floor personnel in real time.
"Providing the operator with as much data as possible via the machine tools' Mazatrol controller is a major aspect of running the plant efficiently" continues Terry Clarke, "Not only can they access the manufacturing program and the forward load on the machine but we also download the component drawing as a pdf file from the main server directly to the Mazatrol Fusion at the relevant machine.
It all adds to overall manufacturing efficiency.
When the new plant becomes active in the coming months having the ability to directly access and interrogate the machines from Bishops Stortford will create a mirror image of our operations in the UK.
"Again, it will enable us to optimise the manufacturing operations," he concludes. Request a free brochure from Yamazaki Mazak UK ...
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