A Yamazaki Mazak UK product story | Edited by the Manufacturingtalk editorial team.

Mazak's Done-in-One strategy utilises its Variaxis and Integrex range of multi-tasking machine tools.

Both of these machine ranges provide the user with simultaneous five-axis machining. This enables all of the machine's axes to operate at the same time, the benefit of which is improved quality of the component and also reduced cycle times as the cutting tool is constantly in contact with the workpiece. This may not be the case on machines that do not have this capability, such as those with simple 3+2 axis control.

For example, the Variaxis range features a bridge frame construction. This provides the platform for the X,Y and Z axis movements, which are then seamlessly combined with the A and C axis movements that are derived from the heavy-duty trunnion. This trunnion set-up allows -120deg to + 30deg of movement in the A axis and a continuous 360deg of movement in the C axis in 0.0001 increments.

The design of the Integrex series permits up to 12 axes to be controlled simultaneously, made up of X, Y and Z axes on the upper turret combined with the B-axis milling spindle, X2 and Z2 on the lower turret, two C axes, one on each turning spindle, and a W axis on the second turning spindle. This versatility allows many components that would normally require several operations, on multiple machine tools, to be completed in a single set-up.

Done-in-One has resulted in a total rethink of how complex, highly accurate and quality critical components can be manufactured in a cost-effective manner. Done-in-One delivers savings in terms of reduced process and lead times, manpower, tooling and fixture costs, floorspace requirement and in-process inventory, more is required to create the ultimate machining strategy. Importantly, it also leads to improvements in component accuracy due to the fact that the part to be machined is only set-up once, thus eliminating any compound errors introduced through multiple machine set-ups.

In a typical manufacturing environment batch quantities of around 20 to 50 are considered the norm when justifying the extended set-up times. This approach results in a large stock of raw material (forgings or castings) at one end of the process and a high value of work-in-progress at the other. In between, the lead time required to produce these parts is extended by the requirement to use multiple machine tools to achieve the finished component. It is not unusual to find as many as six, cell-based, machine tools working on one component. These machines are locked in to producing that particular batch, which severely restricts the flexibility of the manufacturing process. This, in turn, requires a disproportionate amount of operator intervention in order to ensure that component quality is maintained.

By applying Done-in-One and utilising the five-axis capabilities of machines like the Mazak Integrex and replacing forged raw material with billets, it is possible to effect reductions in set-up times of over 90 per cent. Material lead times can be reduced by an equal amount if all components are manufactured from the same diameter bar stock. The cost of waste material when machining from bar (which can, of course be recycled) is negligible in comparison to the savings made in material inventory while the overall material cost of barstock is much less than that of forgings.

A major supplier to the commercial airline sector has benefited from Yamazaki Mazak's input to reduce the previous 'made from forgings' lead time of 27 weeks down to just two weeks. This result was of vital strategic importance to this particular customer, which was faced with a requirement to increase build/kit quantities by 33 per cent. The savings that are being achieved by utilising these machining strategies cannot be ignored.

Done-in-One is a perfect example of lean manufacturing, with a direct impact on the bottom line for manufacturing companies facing cost-down pressures from their customers. However, many companies, particularly small- to medium-sized businesses, have still to be convinced of Done-in-One's relevance to their business, despite the accumulated evidence that can be put forward. Their counter argument is usually one of cost, believing this strategy to be too expensive and too complicated for their particular requirements.

Potential customers can place too much emphasis on the initial cost of a machine tool, often ignoring the financial benefits that using modern technology and machining strategies can bring. It is here that Mazak is working to convince potential customers that the Mazak option of Done-in-One is affordable and can be applied to a multitude of application areas and component types.

April 2009

The Mazak Variaxis 630-5X II-T has become a true multi-tasking powerhouse with the addition of turning capability for the table on the vertical spindle, five-axis machining centre. The first of its kind to feature an integrated turning capability, and controlled by the industry's most advanced and operator friendly CNC, Mazatrol Matrix, this powerful multi-surface machine tool is now more versatile than ever.

The inclusion of turning capability built in to the Direct Drive C Axis table demonstrates a continued ingenuity in machine tool technology, yet more importantly it offers the manufacturer a greater ability to machine large, complex parts in just a single setup.

The Variaxis 630-5X II-T features a 30kW integrated main milling spindle with 18,000 rpm as standard. The compact nose on the main spindle is designed to maximise the machining envelope to accommodate a wider variety of parts for processing. With the introduction of the turning spindle, turning can be accomplished with the tilting rotary table at 0-degree or 90-degree positions with an 18.5 kW motor and speeds of up to 1100 rpm. The rotary table can carry a 530mm chuck and a maximum work envelope of 730mm in diameter by 500mm in height.

High-speed processing of the large amounts of data that high-precision simultaneous five-axis machining requires is readily accomplished by the Mazatrol Matrix CNC. Software and hardware advances in the Mazatrol Matrix include powerful internal computing speed from a 64-bit twin-engine CPU, feedrates for machining complex curved surfaces are two times faster than the previous CNC and the servo control technology minimises vibration. 

The Mazak Variaxis 630-5X II-T

More importantly, software capabilities make the Mazatrol Matrix easier and safer to program and operate. A unique Voice Advisor verbally informs operators of machine alarms and switch settings in manual operation to allow simpler part setups and to reduce problems caused by operator error.

Enhanced visual 3D simulations allow the operator to identify and correct any interference conditions prior to machining, as well as part program simulations can be run while the machine is operating, further reducing  machine setup times and overall process time.

Already the Variaxis 630-5X II is the strongest, most versatile and powerful 5 axis vertical machine tool in its class, now the Variaxis 630-5X II-T with turning offers even greater machining capabilities on the one machine, reduced set up times, and more value to your business.

October 2008

As we see machine tool companies continually rolling out the latest series machines at events such as EMO and JIMTOF, one might wonder how a particular model or machine range can significantly differ from its predecessors, in what is often a relatively short space of time.

Speed of CNC processing, axis and spindle response times are continually being improved. These incremental advances whilst appearing small can actually lead to significant improvements in machine performance.

Therefore, it’s testament to the fiercely competitive nature of the industry and specifically, one of its innovative leaders Yamazaki Mazak Corp, that manufacturers like Robert Lange, Managing Director of Lange Engineering in Geelong, has been able to record increases in productivity with their newest Mazak vertical machining centre, which would normally only be achievable through an upgrade to a multi-tasking machine.

Mr Lange and the Mazak VCN 510C-II

Lange Engineering is involved in the manufacture of automotive, transport and general engineering components, and like all machine shops, is constantly searching for ways to increase profitability. Recently they switched the manufacture of their ‘hammer head part’ (pictured) from using a Mazak VTC 200B vertical machining centre and a milling machine, to a Mazak VCN 510C-II vertical machining centre with HyperMILL© CAD/CAM software, which was utilised to assist with the programming of complex shapes on the rear side of the part.

As you can see, this part requires machining on multiple faces including a combination of milling, drilling, boring, reaming and circular generation of diameters. With the changeover to the VCN, the number of setups on the part has dropped from nine to four, cycle times have dropped from 240 mins to 190 mins and total production time from first to last process is down by 21 percent. With these improvements, Lange Engineering has witnessed a 22 percent increase in profitability on production of the adaptor.

Interestingly enough, manufacturer’s will always tell you that this kind of improved productivity cannot be simply put down to something as black and white as the increase in speed and power of the VCN 510C- II. Rather the Lange example suggests it is a combination of improvements in the machine, the controller and its programming that is helping provide what is essentially an extra day’s worth of production per week.
Features of the VCN 510C-II include:
• Improved machine rigidity for improved accuracy. The degree of machine rigidity dictates the degree of machining accuracy, accuracy being vital in reducing the amount of errors in production.
• The ability to save time by programming complex machining operations offline using the HyperMILL© software.
• Improved real-time programming using the powerful, user friendly and standardised CNC controller, Mazatrol Matrix.
• Increased spindle power and speed from 10,00rpm to 12,000mm/min.
• Increased traverse rate of 30,000 mm/min to 36,000mm/min with higher acceleration.
• An overall faster turn around on parts resulting in more production.

In the 14 years since their first Mazak purchase back in 1993, Lange Engineering now has 10 Mazak machining centres and lathes in production, with another large lathe on the way.

Robert attributes this continuing investment in Mazak machinery to their leading design, specifications, reliability and user friendliness while noting that as these machines have grown in power, speed, functionality, features and ease of use, they actually cost the same amount today as they did ten years ago. Couple this with the 40 percent increase in production at Lange over those 10 years, and its no wonder Robert has continued his partnership with Mazak and John Hart for so long.

March 2008

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.  

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

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

“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.

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.

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