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Customer
Manufacturer of Hydraulic
Valves
Problem
The company’s outdated valve line was labor-intensive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.
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."
Contact cvitale@toyoda.com for
the full case study |
