Are you grappling with the complexities of modern manufacturing, facing labor shortages, or constantly seeking ways to boost productivity and reduce operational costs? The world of manufacturing is evolving rapidly, and embracing flexible automation solutions is becoming not just an advantage but a necessity for many businesses.
The insightful discussion presented in the video above, captured at Okuma’s Open House, sheds light on the transformative power of industrial automation. It features Chris Davala, an expert from Okuma, who elaborates on how various automated systems are being implemented to revolutionize shop floor operations. This accompanying article will delve deeper into the strategies and technologies discussed, providing a comprehensive understanding of how these solutions can be leveraged to achieve mind-blowing cost savings and unparalleled efficiency.
Addressing the Workforce Challenge with Automation
One of the most pressing issues in manufacturing today is the persistent labor shortage. Finding qualified personnel willing to undertake certain repetitive or demanding tasks has become increasingly difficult, particularly in the post-COVID era. It is understood that automation steps in to bridge this gap, ensuring that the demand for parts can continue to be met.
It is important to clarify that automation is not merely about replacing human labor; rather, it is viewed as a strategic shift in job roles. The concept of the “three D’s” – dull, dirty, and dangerous jobs – is often referenced in this context. These are tasks that are typically undesirable and can be performed more efficiently and safely by machines. Consequently, human workers can be transitioned into higher-value roles, such as robot programmers, maintenance technicians, or individuals engaged in more complex, creative problem-solving. This reallocation of human capital allows skilled employees to focus on tasks that truly leverage their expertise and ingenuity, leading to greater job satisfaction and overall company profitability.
Enhancing High-Volume Production with Integrated Systems
For manufacturers dealing with large batches of identical parts, specialized automation systems are often considered indispensable. The video highlights an excellent example: the Okuma 2SP-2500, a twin spindle horizontal lathe. This machine is equipped with dual robot gantry arms and 16-station stackers, making it ideal for continuous, high-volume operations. Parts are loaded and unloaded autonomously, allowing the machine to run for extended periods without constant operator intervention. This setup is particularly beneficial for industries such as automotive, where high throughput and consistent quality are paramount. Operations (OP) 10 and OP 20 can be performed seamlessly, ensuring an uninterrupted flow of production.
Simplifying Grinding Operations with User-Friendly Automation
Grinding operations have historically been a domain of manual labor, with operators meticulously loading and unloading parts due to the critical nature of the finish operation. Parts at this stage often represent a significant investment in terms of time and material, prompting a desire for human oversight to prevent errors. However, advancements in industrial automation have introduced solutions that make grinding more efficient and less dependent on continuous manual input.
An exemplary system mentioned in the video is the Load & Go, which is characterized by its simplicity and ease of integration. This type of automation can be quickly set up in front of almost any machine. The teaching process is streamlined, requiring only a few points to be defined for operation. Imagine if a system could act as a reliable, tireless operator, handling the repetitive loading and unloading tasks, thereby freeing up your skilled technicians for more intricate work. Such simple, flexible automation is fundamentally changing perceptions in the grinding world, allowing for greater consistency and throughput without compromising precision.
Mastering High-Mix, Low-Volume Production with Intelligent Pallet Systems
While high-volume production clearly benefits from automation, the challenges of high-mix, low-volume (HMLV) environments often seem more daunting. However, flexible automation solutions are specifically designed to excel in such scenarios, offering unparalleled versatility.
The Daifuku Cell: A Hub of Multi-Job Flexibility
The Daifuku cell, as demonstrated with two Okuma MB 5000 horizontal machining centers, is a prime illustration of HMLV mastery. Far from requiring high volumes to justify its existence, this system thrives on variety. With an impressive 27 different pallets, each can be configured for a unique job. This allows for tremendous flexibility: setting up multiple jobs on individual tombstones, running 27 different jobs, or even multiples of the same job. A significant advantage is the ability to perform all setups during the day using high-value operators and then allow production to run unattended throughout the evening. This eliminates the need for second or third shifts, maximizing profitability and ensuring high spindle uptime.
The Fastems Cell: Vertical Integration for Space Efficiency
For operations constrained by floor space but possessing vertical clearance, the Fastems cell offers an innovative approach. This modular system, which can be configured with one, two, or three rows high, essentially creates a vertical storage solution for pallets. Similar to the Daifuku cell, it is ideally suited for running setups during the day and unattended production at night. A key feature of the Fastems cell is its intelligent cell controller. This sophisticated software can make autonomous decisions based on available tools, programs, and even scheduling software, prioritizing jobs by due dates. Consequently, the burden of scheduling and decision-making is partially lifted from shop floor personnel, allowing them to concentrate on the craftsmanship of making parts, while the system intelligently manages the workflow.
The Rise of Collaborative Robotics (Cobots)
The evolution of robotics has brought forth collaborative robots, or cobots, which are designed for safer, more interactive operations alongside human workers. Traditional industrial robots are typically larger, more powerful, and necessitate extensive safety enclosures. Conversely, cobots are engineered with features like less aggressive torque motors and instant stop capabilities upon contact, making them inherently safer for human interaction. This is often visually indicated by green stripes or components on the cobot’s structure.
A Fanuc cobot showcased in the video exemplifies this trend. Mounted on a mobile cart, it can be easily positioned in front of various machines and taught a few operational points. This portability and ease of programming allow it to function effectively as an automated operator, handling repetitive tasks. While concerns about safety with specific applications, such as polishing sharp objects, are sometimes raised, it is generally accepted that proper use within intended parameters ensures a safe working environment. The adaptability of cobots represents a significant step forward in making automation accessible and practical for a wider range of manufacturing tasks, contributing to greater overall manufacturing efficiency.
Unlocking Potential with Horizontal Machining Centers
Horizontal machining centers (HMCs) offer distinct advantages over their vertical counterparts, particularly when integrated with flexible automation solutions. A primary benefit of HMCs stems from the orientation of their spindle.
Superior Chip Evacuation and Tool Life
With a horizontal spindle, gravity becomes an ally in chip evacuation. Chips naturally fall away from the cutting zone and are efficiently flushed out by coolant, preventing accumulation on the workpiece or fixtures. In contrast, on a vertical machining center, chips tend to pile up on the table, necessitating frequent cleaning to maintain accuracy and prevent tool damage. This superior chip management in HMCs contributes to longer tool life, better surface finishes, and a cleaner machining environment. Furthermore, the ability to utilize tombstones on HMCs allows for multiple parts or multiple sides of a part to be machined in a single setup, further optimizing production.
Increased Spindle Uptime with Two-Pallet Changers (2 APC)
Even the simplest forms of automation can yield significant gains. A 2 APC system, featured in the video, allows an operator to load parts onto one pallet outside the machining environment while the machine is actively cutting parts on the other pallet internally. The only downtime observed is the brief moment of the pallet swap itself. Imagine if the setup time for a part could be completely eliminated from the machine’s operational cycle. This effectively doubles the machine’s productive time, resulting in significantly higher spindle uptime and, consequently, greater profitability. The flexibility of tombstones, with their two or four sides, means that the complexity of parts and workholding setups is largely limited only by one’s imagination.
Precision and Prediction with Advanced Software: Surface Guide and Hyper-Surface
Achieving the best possible surface finish, especially on complex, one-off parts, has traditionally involved a painstaking process of trial and error with speeds, feeds, and depths of cut. However, cutting-edge software solutions are now making this process more predictable and efficient.
Okuma’s Surface Guide is a revolutionary product that takes CAM software output and analyzes it for imperfections and irregularities within the tool path. This analysis generates a visual “color map” that clearly identifies potential problem areas. Complementing this is Hyper-Surface, Okuma’s proprietary software, which makes intelligent decisions about the tool path itself. It works to smooth out any inconsistencies detected in the model or due to machine characteristics. Imagine if you could identify and rectify potential surface finish issues *before* a single chip is cut. This capability dramatically reduces the need for multiple iterations and adjustments, ensuring a better, more consistent surface finish right out of the box.
The demonstration presented in the video, showcasing parts with “rough, rough, semi-finish, finish, and finish +” examples, powerfully illustrates this technology’s impact. It highlights how different CAM software outputs can vary, and how Surface Guide can predict the outcome. By allowing manufacturers to visualize and correct tool path imperfections pre-emptively, significant time and cost savings are realized. For instance, a part that might typically take 18 hours to run, or require numerous fine-tuning attempts, can now achieve the desired finish on the first try, leading to truly flexible automation solutions.
Your Flexible Automation Q&A: Unpacking the Savings and Efficiency
What are flexible automation solutions?
Flexible automation solutions help manufacturers improve productivity, reduce operational costs, and address labor shortages by automating various tasks efficiently.
How does automation help with labor shortages in manufacturing?
Automation addresses labor shortages by taking over repetitive, dull, or dangerous tasks, allowing human workers to transition into higher-value roles like programming or maintenance.
What are ‘cobots’?
Cobots (collaborative robots) are designed to work safely alongside human workers, often having features like less aggressive motors and instant stop capabilities. They are typically portable and easy to program for repetitive tasks.
What is a main advantage of Horizontal Machining Centers (HMCs)?
Horizontal Machining Centers (HMCs) offer superior chip evacuation, which helps prolong tool life and keep the machining area cleaner. They can also increase productive time through features like two-pallet changers.
How can advanced software improve machining results?
Software like Okuma’s Surface Guide can analyze and identify potential surface finish issues in a tool path before machining begins. This helps achieve better, more consistent finishes and saves time by reducing trial and error.