Product category:
Flexible machining cells and systems (FMS)
News Release from: Yamazaki Mazak UK | Subject: 5-axis, three machining centre FMS
Edited by the Manufacturingtalk Editorial
Team on 17 May 2007
FMS reduces aerospace machining set-up
times
Three continuous path 5-axis machining centres are linked by a pallet handling system - handling 30 pallets - to form a low volumeflexible manufacturing system for aerospace parts.
Three continuous path 5-axis machining centres are linked by a pallet handling system - handling 30 pallets - to form a low volumeflexible manufacturing system for aerospace parts Hampson Aerospace Machining Birmingham is the headquarters and main manufacturing facility for the aerospace manufacturing division of Hampson Industries
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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A programme of investment since this facility was opened in 1999 has seen major investment in machine tools and manufacturing systems.
One of the latest acquisitions to be installed in the 64,000ft2 machine shop is a Yamazaki Mazak Palletech manufacturing system linked to three Mazak Variaxis 630 5X II simultaneous 5-axis machining centres.
Hampson Aerospace Machining Birmingham's decision to invest in the Palletech system was driven by the mix of medium to large prismatic components that it machines and, in particular the fact that these components are manufactured in relatively small batch sizes.
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"The typical prismatic parts that we machine for the aerospace industry are oil tanks, filter housings and covers in aluminium and a variety of engine parts in titanium.
These bring with them problems of manufacturing efficiency due to the relative low volumes that are required and the fact that our major customers require us to manufacture in kits of parts," said Danny Close, Hampson Aerospace Machining Birmingham's programme director.
"Because of this we were faced with an increased amount of inefficient set-up time, mainly changing fixtures from one component to another.
The implementation of a 30 pallet FMS has allowed us to leave the majority of fixtures in-situ on individual pallets, resulting in dramatically reduced set-up times." The move to the Palletech manufacturing system was a major technology hike for Hampson Aerospace Machining Birmingham (HAM Birmingham) simply because it had always used stand-alone CNC machines up to this point.
The change from stand-alone machines to an FMS involved quite a long learning curve, something that was made easier by the assistance provided by Yamazaki Mazak in regard to component development and planning and scheduling work.
This situation was complicated by delays in the Airbus A380 programme, for which HAM Birmingham is a contractor, that resulted in other, less suitable components having to be machined on the Palletech system.
"However," added Dr Alan Duffield, Hampson Aerospace Machining Birmingham's Divisional Sales and Marketing director, "We are currently undergoing a review of the components we manufacture and are actively seeking more prismatic work to add to the components we are currently machining as we can see we will have created more capacity from early 2008.
Now that we have the Palletech system in place and we know a lot more about how to get the best from the system, the result will be that we will be highly competitive thanks to the efficiencies that having 30 pallets makes." He said: "The ideal scenario, of course, is to have all 30 pallets full, with no one component exceeding the 80 tool capacity of the Variaxis machines - then Palletech would be highly efficient and difficult to compete with thanks to its ability to run lights out.
Those parts would typically be components such as pump housings manufactured from castings in light alloys or titanium as those are our areas of expertise." HAM Birmingham is making further productivity gains through the relocation of a fourth Variaxis 630 5X II machine next to the Palletech system.
This stand-alone machine was initially used for component development work but is now proving more valuable for preparing components with datum faces prior to them being transferred to the Palletech system.
Previously this work had been carried out on jig boring machines, which was not only time consuming but created its own problems as other work that required the specialist features of the jig borers was being delayed.
"The decision to relocate this Variaxis immediately next to the Palletech system brought immediate benefits in logistics, production and manpower efficiencies," said Close. Request a free brochure from Yamazaki Mazak UK ...
"Our ongoing business plans include a definite strategy to grow and diversify our customer base and by implementing the Mazak Palletech system we can see significant opportunities to meet these aims in the next 12 months.".
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