Implementing A Machining Cell
FMS/Cells & FA550

CHALLENGE

Manufacturer of lasers produces parts that are highly complex prismatic workpieces with only occasional requirement for contouring. The company’s materials considerations run from about 80 percent aluminum to copper alloys and various high-alloy stainless steels. Lots average about 25 to 50 parts, but lots of one are not unusual.

TOYODA SOLUTION

Toyoda FA550 Horizontal machines supported by a rail guided vehicle and a three-tiered, 12 pallet stocker controlled by a touchscreen cell controller.

Because of the complexity of the part mix, the 120-tool magazine of the Toyoda FA550 was attractive. The stability and resultant accuracy of this model (weighing in at 15 tons) was also a consideration. But, most important to the company was the willingness of Toyoda to act as a technology partner for the long term – five years and beyond.

Another reason behind the choice of the new horizontals was the expansive work areas. The machining envelope is almost 12 cubic feet. Workpieces larger than the envelope can be accommodated because of the unobstructed splashguard design coupled with oversized doors and long spindle clearances.

Results

The new cell was installed within five weeks. It took only seven days to get it up and running prototypes, and nine days to run scheduled parts. The main goal is to run 24 hours per day less maintenance, manning two out of every four shifts.

The cell is the culmination of a four-year JIT plan that was launched when the company moved from its current location to a new smaller facility. Now 60 employees produce three times the business in 20,000 square feet.

Contact cvitale@toyoda.com for the full case study