Challenges

1. Since manual machines were used, the production output varied depending on the operator’s skill.
2. It is desired to reduce material costs as much as possible in order to respond to demand for increasing the production volume.
3. It is also desired to perform more advanced quality control.

To solve the above challenges that the customer had, we proposed “automatization of production line by introducing our multi-tasking machine”

Solutions

Our proposals consist of “integration of machining, deburring, and marking processes;” “machining of 4 parts from a single material;” and “creation of machining program by using CAM”.

1. Integration of Machining, Deburring, and Marking Processes

Our multi-functional MT100 has a live tool function, which enable drilling on the end face of a workpiece, deburring, and marking on the sides of the workpiece. In other words, lathing, machining center (drilling), manual operating tools (deburring) and marking operations that usually require three kinds of machines can be performed in a single machine.

That eliminates variation in production output caused by different skill levels among operators, allowing for stable volume of production.

2. Machining of 4 parts from a single material

It is now possible to produce multiple finished parts from a bar material instead of Cutting material one by one as conventionally done.

Applying this preset number parts production has also contributed to the material cost saving.

3．Creation of machining programs by using CAM

In order to respond to increasingly complicated product shapes and complex operations through process integration, the optimum machining programs can be created with CAM from the data on workpieces, machines, and cutting tools.
In addition, the processing simulation function enables any interference in the machining area, as well as cycle time, to be checked without using actual equipment.
Therefore, careful study can be made for new workpieces without stopping the on-going operations of the equipment, leading to shorter start-up times for machining new workpieces.

We are determined to work seriously on the customer’s issues, propose various ideas, and clear the hurdles in cooperation with the customer.