Cutting time and costs with multi-tasking

Featured in Australian Manfacturing Technology magazine, November 2007

We hear so much about multi-tasking machine tools improving productivity, part quality and increasing profitability, but how do small manufacturers justify the investment when they can already produce the parts they need on existing machinery?

Murray Clair, Managing Director at Nupress Tools Pty Ltd in Cardiff NSW is only too happy to tell us how. A long standing partner of John Hart and Mazak, Nupress have installed 13 Mazak machines to date with the latest being an Integrex 200S-IV, 5-axis multi-tasking machine.

Looking at production of a clevis part produced on the Integrex at Nupress, it is clear that there are huge advantages in multi-tasking.  In terms of production figures, Nupress has been able to greatly reduce process production times, as well as removing the need for substantial quantities of a particular part for a production run.

For example, the clevis part pictured previously required multiple machine setups and a minimum batch size of 20 to be viable. Total operations on the part included 7 separate setups on 4 different machines, with additional in process hand de-burring. While the cumulative cycle time of machining the part was only 21 minutes, the total production time on the batch was 5 full days.

Moving production of the clevis part onto the Mazak Integrex 200S-IV, Nupress was able to remove the need for minimum batches, as the part could now be machined in a single setup with a process that takes only 17 minutes.

So while the cycle time has only been reduced by 4 minutes, the total process time to machine 20 parts has been cut from 5 days, to 5.5 hours, as 7 setups have become 1. Also, as Nupress no longer needs to machine 20 parts per process over an entire week, they can now set up the Integrex in the morning and deliver complete parts to a customer that afternoon. 

Financially speaking, the savings achieved with the new machine are easy to see. The drop in operating costs from four machines to one is significant, and the increased efficiency and productivity as a result of no time on the floor for the clevis part, is a great advantage for Nupress.  Additionally “Done in One” machining allows Nupress to increase production output per skilled machine operator, and increase production flexibility to better meet customer demands. Now the production scheduler at Nupress doesn’t have to spend a whole week coordinating multiple machines as he can focus on producing more of his other longer run parts on the four now available machines that were all originally required for the clevis.  

The production team at Nupress identified the new found ability to quickly meet customer’s needs and orders as one of the many justifications for the investment.  In addition to this, Nupress has a North American office and facility located in Toronto Canada, the “Done in One” flexibility enables them to meet demanding export air freight schedules for dispatch to North America. They also cited the availability of service and spare parts from John Hart, the specifications of the machine, and the reliability of Mazak machines as other key buying factors.  
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Over 13 years, with 13 Mazaks, and another Integrex on order, Nupress have established a strong and successful partnership with John Hart and Mazak.  The new Integrex 200S-IV at Nupress is really proving that “Done in One” machining is possible, and Murray Clair and the team at Nupress couldn’t be happier.

Murray Clair, Managing Direcor at Nupress with the Integrex 200S-IV

November 2007

The key benefits of multi-tasking

Taken from MS eye Watch - Summer 2007 edition.
Visit http://www.machsys.com/ew/Summer07/index.html for more

Machine tool leader Mazak Corp. introduced multi-tasking by marrying an automatic tool changer and two-position spindle with a slant-bed lathe in the mid 1980's. While a powerful new way of thinking about machining processes was born, the challenge of designing for the multi-tasking capability is ongoing, says Brian Papke, President. The goals of multi-tasking include the following:

1. Reduce direct cost -- fewer machines, fixtures, tools and far less labor.

2. Slash non-value-added time, multiple setups, part handling and queue time.

3. Compress lead-time -- from days or weeks to hours.

4. Improve cash flow -- smaller, frequent shipments on customer demand.

5. Reduce work-in-process (WIP) inventory -- releasing cash for operations/investment.

6. Improve part accuracy -- no tolerance build-up from multiple setups.

7. Reduce indirect costs -- less floor space, utilities and maintenance.

8. Reduce lot sizes with no cost penalty -- lots-of-one or assembly kits.

9. Run "lights-out" with automation -- more cutting time with no added labor.

10. Improve customer satisfaction. 11. Improve competitiveness -- seek new customers and markets.

12. Greater profitability.

Click here to see our range of Mazak Multi-tasking machines

July 2007

Mazak Minokamo Plant 2 opens

“Yamazaki Mazak Minokamo Corporation, Minokamo Plant 2,” the 8th Mazak manufacturing plant in the world has started operation.

The new Minokamo Plant 2 factory, near Yamazaki Mazak Minokamo Corporation, is an integrated production plant for the all 37 NEXUS II series, the New Generation World-Class Machine Tools, and other machine tool series.

All 37 NEXUS II series, the QUICK TURN NEXUS II series, the VERTICAL CENTER NEXUS II series, and the HORIZONTAL CENTER NEXUS II series, as well as the IVS series, the MULTIPLEX series and flat-bed CNC turning centers are produced here. The NEXUS II series are the best selling Mazak machines, which are produced at all 7 Mazak factories world wide. 200 Nexus II series machines will be produced each month at the new Minokamo Plant 2.

A variety of latest production systems for shorter in-process time is used in this factory such as the "Mazak Production On Demand" system, which is already in use by all 7 Mazak Cyber Factories, the latest machining equipment, efficient assembly layout to reduce unproductive time, and a variety of equipment for a better factory environment.

Other factories in Japan will be able to have more space and production capability thanks to moving most NEXUS II series to the new manufacturing facility which is a staggering 136,000 square meteres (33.6 acre) in size. Minokamo Plant 2 provides customers high quality machine tools designed for high productivity.

To view a map of the factory, click on the image to the right.

To read more on the NEXUS II series click here.

Mazatrol MATRIX- The intelligent control solution

As you would expect from one of the pioneers of conversational programming, Mazak’s new Matrix CNC controller delivers elements that take machine control and machining to new levels of efficiency.

Within Matrix are five key elements that distinguish it from other control systems: Intelligent Safety Shield; Virtual Machining; Active Vibration Control; Intelligent Thermal Shield; and new Mazatrol programming functions.

1. Intelligent Safety Shield provides the user with active collision monitoring, whether the machine is used in manual or full CNC mode, resulting in the virtual elimination of collisions and the consequent downtime and costs associated with them.
2. Virtual Machining monitors potential collision points during the creation of the NC program, and as a result the time required to complete the programming operation is greatly reduced.
3. Active Vibration Control uses fine resolution encoders and more powerful servo drives to eliminate the negative effects of machine vibration on component quality. Matrix is able to do this by monitoring and modifying axis movements ‘on the fly’.
4. Matrix’s Intelligent Thermal Shield reduces the effects of heat dissipation by identifying any potential localised areas of heat build up and eliminating them, while channelling heat away from the machine area.
5. Over 100 new programming functions have been created to assist in the programming of the machine by simplifying the process and improving cycle time. They include the Mazatrol Mill-Turn cycle, and the addition of the ability to machine on two spindles and two stations simultaneously.
In addition to these 5 key elements, the key features of the controller are:

• Users have the capability to control nine axes, with high accuracy machining ensured by a sub-micron (0.0001 mm/0.00001 inch) minimum program increment.
• The enhanced conversational capability caters for even more complex shapes.
• Pulse encoders contribute to a high quality surface as does Quadrant Spike Compensation, minimising axis ‘slip-stick’ during machining operations.
• The Mazatrol Matrix incorporates a 64-bit ‘twin engine’ processor to cope with huge amounts of data generated during machining.

Featured on Mazak Quick Turn NEXUS, Vertical Centre NEXUS, Horizontal Centre NEXUS, Integrex IV series, Integrex e-Series and Variaxis machine tools.

October 2006

To read more on Matrix click here.

10,000 NEXUS machines sold

In July 2002, Yamazaki Mazak Corporation introduced ten different models of the Quick Turn Nexus and Vertical Centre Nexus series to the market. These new machines featured a design concept that combined Advanced Technology, High Performance and Exceptional Value. Additionally, the manufacturing of all Nexus series was simultaneously started in Mazak’s five Cyber Factories, two in Japan, one in the USA, one in the UK, and one in Singapore.
The initial machines introduced were two axis CNC lathes in four model sizes and three model sizes of vertical machining centres.
Since then, the Nexus series has been expanded to offer faster feed rates, higher accuracy on selected models, and mill / turn multi-tasking capability in order to meet a wide variety of customer requirements. The size range of the Quick Turn Nexus series has been expanded and two models of Horizontal Centre Nexus have also been introduced.
Some of these newer models were only introduced in 2004 and 2005 and currently, a total of thirty four Nexus machine model variations are produced by Mazak’s Cyber Factories.
The complete Mazak Nexus range has been very well received by customers worldwide and more than 10,000 Nexus machines had been sold up to December 2005 - just three years and five month since their initial introduction. John Hart Pty Ltd sold in excess of 100 Mazak Nexus machines in this period.
Yamazaki Mazak continues to develop the Nexus series in order to meet customer requirements and provide before and after sales service and support through the Mazak global support network and local distributors.

May 2006

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