Apply lean
manufacturing machining technology on low pressure aluminum hydraulic servo valve
body family-of-parts to reduce lot size, number of
machining operations,
setup
time, run time, queue time, and lead time, and increase inventory
turns.
Manufacturing
Alliance Associates, Inc. 720 Maple Road, East Aurora, New York
14052-1012
716-652-4510
Since
1993 implementing technology for businesses where resources are non-existent
or during a growth
initiative.
APPROACH:
horizontal
machining
center with pallet shuttle
workholding
and
tool holders and cutting tools
custom
macro B and parametric programming
automated
workpiece
and tool probing
broken
tool detection
RESULT:$20 (labor + material) main component
to a
$156
assembly cycle
tested and shipped for $800 to $3,200.
BASELINE
PART BASELINE
PART NOMENCLATURE FAMILY-OF-PARTS
FAMILY-OF-FEATURES
FAMILY-OF-TOOLS FAMILY-OF-MACROS (FANUC CUSTOM
MACRO "B")
COMMERCIAL ALUMINUM ALLOY BAR STOCK CUT TO
DIFFERENT LENGTHS
SAME WORK HOLDING JAWS FOR PALLET 1
6 SIDES MACHINED IN 1 OPERATION WITH 1 PALLET SHUTTLE.
3 SIDES PER PART; 8 PARTS PER PALLET; 2 PALLETS.
48 WORK OFFSETS (X, Y, Z & B AXES); 24 PER PALLET.
PALLET 1 AND PALLET 2 WITH AUTO LOADED WORK OFFSETS AND PALLET
2 AUTO PROBED WORK OFFSETS.
120 MAGAZINE WITH PROGRAMMED AUTO LOADED TOOL OFFSETS
QUICK CHANGE VISE JAWS; PALLET 1 SAME JAWS FOR ALL PARTS IN
FAMILY.
WORK AND TOOL PROBING.
BROKEN TOOL DETECTION.
UNATTENDED MACHINING (GHOST MACHINING).
LOAD IDLE PALLET WHILE OPPOSITE PALLET IS IN CYCLE
