Aerospace Company Manages Rapid Growth with Flexible Manufacturing System

Located in Wichita, the heart of American aerospace manufacturing, Product Manufacturing Corporation (PMC) has been supplying the commercial aircraft, aerospace and defense industries for more than 50 years.

With so much competition in an industry that holds the highest of standards, PMC President Chris Lette knows how crucial it is to have the right manufacturing partners and machining equipment in house. Over the past several years, manufacturing processes have trended toward leaner work environments, maximizing output and turnaround times, while minimizing manual operations and tooling setup and changeover times.   

Four years ago, Lette and PMC Vice President Rick Wolf started evaluating automation as a way to reduce costs and time associated with manual operations. Not only could automation reduce production times and operator involvement, it was a sound foundation for PMC’s future growth opportunities.

“Automation provided the solution we needed to strengthen our existing processes and grow as a company,” explains Wolf. And this seems to be exactly what resulted—in the past six years, the company has grown from $5 million to $35 million per year.

Today, PMC utilizes two Toyoda Flexible Manufacturing Systems (FMS), with mirrored layouts for centralization of loading stations and all materials. The first system features three FA450-III HMCs and two loading stations for 48 pallets, machining almost entirely aluminum. The second system features three FA550-II HMCs with two loading stations and 28 pallets for machining a mix of aluminum, titanium and steel workpieces.

These flexible systems are made up of modular equipment and software, allowing them to expand as the company continues to grow. Currently, PMC is running more than 300 different parts for several major aerospace manufacturers. Because PMC is able to keep fixtures and tooling set up on every pallet, they’re able to turn parts around in a day. This speed-to-customer turnaround keeps PMC securely positioned in the competitive aerospace industry.

The systems’ Mach III cell controller software allows PMC to store programs for all existing and new part setup. All jobs are then scheduled into the production flow, keeping all projects on target for on-time completion. This software helps increase machine and operator productivity by optimizing production schedules and automating workflow. 

Another feature of the installations that helps PMC reduce tool-change time and maximize spindle time is the stationary tool storage rack on each machining center. These 120- or 230-tool magazines utilize a four-position revolving disk to stay tooled for multiple part numbers. The Matrix keeps the next tool ready and waiting to be switched in by the machine’s tool-changer arm while the machine is in use.

“To be successful in the aerospace industry, PMC had to incorporate the right equipment. These Toyoda installations provide PMC with the technology and capability to operate at peak efficiencies,” explains Regional Sales Manager for Toyoda, Mike Goodger.

“This equipment has allowed us to cut manual operation in half. Now, the operators can focus on more strategic roles in scheduling, reporting, and workflow management,” explains Wolf. 

In the past several years, the facility has more than doubled in size at its current location, with construction on a new facility to begin soon. According to Wolf, the Toyoda systems are helping the facility accommodate and manage the rapid growth the company is experiencing. With the right equipment in place and a stronghold on its position in the marketplace, PMC is positioned for continued growth and success.

Roberts Tool embraces lean manufacturing, and is constantly analyzing their processes, identifying ways to eliminate production bottlenecks and produce parts at lower costs