Hampshire-based Innova Design & Build Ltd recently invested in a pre-owned five-axis machining centre with integrated automation.
This machine, a Mikron UCP 600 Vario with seven-station automatic pallet system, is designed for 3+2 positional and full simultaneous five-axis machining; it was installed at the company’s Emsworth facility (near Portsmouth) in October 2013 and is being used to machine a range of complex, high-precision components for the aerospace, marine, rail, space and electronics sectors.
Managing director Hugh Watson says that Innova bought its first five-axis machine six years ago. “The type of manufacturing we’re involved in is characterised by short production runs — prototypes and one-offs through to medium-volume batch sizes — with an emphasis on part quality, short lead times and cost-competitiveness. We knew that the nature of our work was ideal for five-axis machining, so we bought a stand-alone machining centre back in 2008, as a route to increasing our productivity and making us more efficient.”
That said, Mr Watson knew that when the time was right, even greater productivity could be achieved by automating the five-axis machining process — thinking that led him to explore the potential of machines with integrated automation.
What he had in mind was automatic work-piece pallet changers and large-capacity tool changers for long, uninterrupted machining, together with advanced CAD/CAM software to drive and regulate the machining process.
“There are 168hr in a week, and my aim is to optimise the machining process so that an absolute minimum of these hours is ‘lost’ in unprofitable activities such as job set-up,” says Mr Watson, adding that what made Innova firm up its plans for a five-axis machine with automation was the opportunity to handle more work for a long-standing customer.
“We could see straight away that the additional workload would put pressure on our existing machining capacity and capabilities, so we set about investigating the automation route more thoroughly.”
Decision time
Key considerations for Innova included whether to invest in a new or pre-owned machine, and the level of automation necessary to deliver the required productivity and performance benefits. “We believed that a ‘universal’ five-axis machine with integrated multi-pallet stations designed for small-batch production yet capable of machining different materials — including aluminium, steel, stainless steel and titanium, for example — would be the best bet.”
The choice was further narrowed by Innova’s decision to invest in a used machine. “New five-axis machines are expensive, so payback takes longer. As this was our first foray into using a machine with integrated automation, we decided to invest in a well-looked-after pre-owned machine with a proven track record.”
Following a visit to the Southern Manufacturing Show in February 2013, where Innova saw GF Machining Solutions’ (
www.gfms.com) five-axis machine tool technology in action, plus a subsequent visit to the Lotus F1 Team’s facility in Enstone to see a number of GF Machining Solutions’ five-axis machines with automation operating in a production environment, the decision was made.
The used Mikron UCP 600 Vario bought by Innova is a compact machine equipped with an 18,000rev/min spindle, a seven-station automatic pallet changer and a 220-tool ATC. The machine provides Innova with much-needed additional manufacturing capacity, and its integrated automation allows the company to run the Vario overnight and at weekends. Indeed, it has been running ‘round the clock’ since January 2014.
Mr Watson says: “The Vario is in constant use. During normal working hours, it is being used to machine a range of parts, and its seven-pallet capacity means that we can load and set up jobs ready for ‘lights out’ operation at night. We haven’t hit 168hr constant production yet, but we’re getting there!”
Innova’s investments are not limited to improving its plant, equipment, processes and systems, as Mr Watson explains. “To increase our manufacturing capabilities and capacity, we have implemented an ambitious apprentice training programme. Out of the 15 people we employ, four are apprentices.”
The company’s apprenticeship programme, which is run in conjunction with local colleges and administered by training and consultancy agency PETA Training Ltd, provides young people with employment, structured training and the opportunity to achieve nationally recognised qualifications.