A flexible manufacturing system (FMS) comprising three Makino A61nx horizontal-spindle, 4-axis machining centres served by an automated guided vehicle running on a linear track along a storage and retrieval system housing 32 machine pallets, loaded and unloaded at two work-set stations, has been installed at the Warwickshire factory of Danfoss UK. The company is a subsidiary of the global, Danish-owned manufacturer of mobile hydraulic and electro-hydraulic products, compressors and speed controls for electric motors.
Operational in October 2023 following its turnkey installation by NCMT, sole UK and Ireland agent for Japanese machine tool manufacturer Makino, the FMS replaces stand-alone production centres for the manufacture of prismatic components in steel and aluminium. They are used in the manufacture of a range of hydraulic integrated circuit manifolds for the mobile hydraulic industry.
The Makinos are capable of machining them all efficiently, as they have a rigid, robust spindle having high rpm as well as high torque. Each horizontal machining centre (HMC) is equipped with a 313-tool magazine, minimising the need to replenish cutters between batch runs, despite production being high mix as well as high volume.
Any pallet with a fixtured component can be routed to any machine, limiting the amount of movement needed, providing considerable flexibility of production and maximising productivity. Machine utilisation is close to 100%, as there is always a part waiting for immediate presentation to one of the spindles. The new, automated system allows the manufacturer to run the facility 24/5 and at weekends when necessary. Two operators manage the cell during each of two day shifts, followed by unattended operation from midnight until 6.00 am.
NCMT supplied applications engineering support throughout the project to enable Danfoss to switch over programs from the previous machines to the new Makinos. The entire project was managed from start to finish, from an empty factory floor to a full programme of operator training.
The manufacturing process starts with a request from a customer via the Danfoss sales team. The system places a request for an operator to load the requisite work onto a specific pallet, which may involve fixturing a single part or several components. The pallet is then scheduled into the FMS. The operator only needs to be in attendance at one of the work-set stations to load and unload parts under instruction from the materials requirement (MRP) system. NCMT, working with Seiki Systems, has now facilitated a new process whereby Danfoss can download orders automatically within the system.
Tony Cave, Production Supervisor at Danfoss UK said, "We didn't know much about NCMT until we started this project. The relationship that has developed between our companies has been really good. All departments within NCMT, from engineering, sales and purchasing through to the senior management, have been very responsive to any queries we have had."
Many benefits are derived from Danfoss UK's new investment. Due to the increased production capacity, machining is being brought in-house that was formerly outsourced to subcontractors. This not only saves cost but also provides greater control over lead-times and product deliveries to customers. Moreover, Mr Cave advises that as experienced staff look to retire over the coming years, the automated FMS will be a big benefit in mitigating the loss of their skills.
He added that all five of the Danfoss group's global factories now use a Makino FMS to produce manifolds, following a strategic decision to align each production site's capabilities. It provides flexibility to allow manufacture in support of worldwide customer demand and specific local requirements.
