Manufacturer of Hydraulic Valves

CHALLENGE

The company’s outdated valve line was labor-intensive and a production bottleneck. Each part required multiple drill and tap operations on each side. This was being done with multi-spindle machines and radial arm drills, with one operator per machine. The customer wanted to increase production, quality and flexibility. In addition, the company’s rural location made it difficult to find skilled labor.

TOYODA SOLUTION

After considering many options, including expensive special-purpose machines, the company decided that horizontal machining centers would provide the solution they were looking for. The Toyoda HMCs allowed them to cut both cast iron and aluminum on the same machine. The HMC fixtures could hold four to eight valve components each, and the machine’s full fourth axis allowed the parts to be machined in one set up. In addition, the twin pallets on each HMC would be fed by an automated pallet loading system. The cell’s 12-pallet buffer stations would keep additional parts and fixtures at the ready.

Equipment Specs

Two FA400 horizontal machining centers were linked in an expandable cell with 12 pallet buffer stations, and two loading stations. All of the tools needed for each program are stored in the 60 and 120 pocket tool magazines of the FA400s. The machines, pallets, loading stations and rail-guided vehicle are all controlled from a single PC workstation on the shop floor next to the cell. Linked to a company-wide network, managers can adjust the production schedule, or check the status of a project, from a desktop PC in the office.

Results

The new cell cut in half the number of different operations required per part. There was also a dramatic labor savings by eliminating repeat set up and tear down. According to the customer, "Deliveries have just gone wild – we ship more products faster and often even the same day. We’ve reduced our inventory while giving our customers faster turnaround, and it’s helped us attract new business as well."