Flexible automated manufacturing cell

Limerick-based Takumi Precision Ltd, a leading global engineering solutions provider, part of the Acrotec Group, has recently invested in a flexible automated manufacturing cell supplied by Leamington Spa-based Mills CNC, the exclusive distributor of DN Solutions’ (formerly Doosan) machine tools and a major automation systems solutions provider to UK and Irish component manufacturers.

The cell, installed at Takumi’s 50,000ft² facility in September, comprises an advanced, and recently introduced, SMX 2100ST multi-tasking mill-turn machine integrated with a SYNERGI Sprint automation system.

The automated manufacturing cell, currently being put through its paces by Takumi’s production and applications engineers, enhances Takumi’s, machining and manufacturing capacity and capability, while at the same time deepening Mills CNC’s relationship with one of Ireland’s leading precision sub-contract manufacturing companies.

Takumi Precision regularly invests in advanced machine tool technologies and, since 2016, has increasingly invested in DN Solutions’ machine tools supplied by Mills CNC. The type and range acquired by the company over the last six years has altered dramatically reflecting and reinforcing the company’s desire and ambition to both consolidate, and strengthen its position within its customers’ supply chains and to become a preferred partner to many of them.

The company currently has over 20 DN Solutions’ machines at its disposal with most organised into discrete and dedicated machining cells for fast and efficient part processing. These machines comprise a number of Lynx and Puma lathes with sub spindles, Y axes and driven tooling capabilities as well as different-size vertical machining centres (VMCs).

Recent acquisitions include two twin turret/twin-spindle turning centres, a compact and flexible five-axis machining centre with integrated automatic workpiece pallet change capability and a high-productivity, multi-tasking mill-turn machine.

Excellent cutting performance
Donal Galligan, Takumi Precision’s founder and CEO, said: “DN Solutions’ machines are reliable, competitively priced and represent great value. They deliver excellent cutting performance and help us achieve the part accuracies, repeatabilities and surface finishes we expect and our customers demand.

“In addition to their performance the machines are backed by Mills CNC’s after-sales service and support which we believe is second-to-none. Dedicated sales, service and applications engineers located in Ireland ensure a fast response and, from our experience, means that any issues affecting machine uptime are dealt with quickly and efficiently.”

Gerry Reynolds, Takumi Precision’s founder and chairman, said: “We consider multi-tasking machines and automation to be the way forward — they help make us leaner, more agile and more competitive. Although the pandemic did impact operations with customers cancelling and postponing contracts, we believed that the hiatus was temporary and were confident that our aerospace and medical business would return.

“We used the time to prepare for that eventuality and, with help from the Irish government via its SBC1 Covid-19 Working Capital Scheme, invested in high-performance machine tools to enable us to ‘hit the ground running’ when it did return.”

The DVF 5000 simultaneous five-axis machining centre, with its integrated 10-postion pallet changer, enables Takumi to capitalise on lights-out production by running the machine unattended, overnight and over the weekends too. During the day it is used to machine prototypes, pre-production parts and jobs with short cycle times, while available pallets are loaded up with raw material for jobs with longer cycle times to run overnight.

Being increasingly involved in many customers’ new product introductions and in designing and proving out machining processes means that Takumi needs to invest in high-productivity standalone machines. Testing, trialling and verifying a machining process, that can often involve numerous iterations, takes time and, rather than tying up a production-led machine with such operations, is best handled on a multi-tasking, standalone machine like the recently purchased SMX 2600.

With business now returning to pre-pandemic levels and demand for Takumi’s high-quality machining services at an all-time high, the company recently made the decision to invest in a second SMX mill-turn machine.

Initially, the intention at the time of order, was for the SMX 2100ST to operate as a standalone machine. However, owing to the company’s experience of investing in automation, and the positive impact made on its performance - Takumi, working collaboratively with Mills CNC, altered the order mid-stream.

Mr Reynolds continued: “The SMX 2100ST, with its lower turret, is flexible, high-productivity mill-turn machine capable of processing complex, high-precision parts in ‘one hit’. The productivity gains experienced from the DVF 5000 investment, got us thinking about whether we could do something similar with the SMX 2100ST.

“After discussing our requirements with Mills CNC, the decision was made to change the original machine tool order – augmenting it with the addition, and integration, of a robot to create a flexible, automated manufacturing cell.”

The 8in chuck SMX 2600ST features 5,000rev/min left and right opposing spindles, B-axis milling function, Y-axis and 12-station lower turret. It is now integrated with a SYNERGi Sprint automation system comprising a Fanuc industrial robot with a 25kg payload, a 900mm x 900mm part load/unload grid plate, end-of-arm tooling, laser floor scanner technology, industrial guarding, and a 17in touchscreen HMI with a separate keyboard. Furthermore, the cell is controlled by Mills CNC’s proprietary SYNERGi software – a powerful and intuitive software solution that incorporates logical navigation and user-friendly menu screens.

Robotic automation system
Mr Galligan explained: “The SMX 2600ST/SYNERGi Sprint cell is the first robotic automation system to be acquired by Takumi in our 24-year history. We are currently putting the cell through its paces and organising our production schedules to be able to take full advantage of this latest investment.”

Takumi Precision’s continuous improvement programmes and strategies are in evidence all across the company’s operations. To complement its investment in new machines, the company has also upgraded its CAD/CAM capabilities by investing in hyperMill - a modular and flexible CAM solution for 2.5-D, 3-D and five-axis milling. Programming using hyperMill, with its one post-processor interface and true-to-detail simulation and collision control, ensures fast and reliable part processing.

To improve lead times and turnround times, Takumi made the strategic decision to augment its operation by becoming a materials’ stockist. This vertical integration decision in addition to acquiring in-house plate and sheet cutting capabilities, has improved operational efficiencies and supply chain management.

Using best-practice methods that include process and machine validation, model-based inspection and CMM technology, Takumi uses MSCOSMOS, Net-Inspect and Digital FAIR (First Article Inspection Report) Management software to streamline its inspection and measuring processes, optimise the flow of information and minimise non-conformance.

Takumi is also installing an in-house treatment and finishing resource at its facility. Created to help reduce customer lead times and ensure better operational and cost control, the resource will include shot peening, anodising, painting, NDT, and passivation treatments.

Meanwhile, MADO, a proprietary ERP system developed by Takumi, provides integrated and seamless management of the company’s main business processes in real time. The system allows different departments to communicate and share information improving accuracy, productivity, reporting and efficiency. It is a transparent system that, through a portal interface, also allows customers access to relevant information pertaining to their specific jobs and the manufacturing processes employed.

In July 2022, Takumi Precision was acquired by the Acrotec Group. Through its group of companies, located mainly in Europe and Asia, Acrotec’s focus is on high-precision technology markets that include watchmaking, medical devices, automotive, aerospace, aeronautics and electronics. Continuing to trade as Takumi Precision, the acquisition will enable the irish company to grow, enter new markets, and provide value for customers and shareholders alike.

Takumi is also significantly increasing its floorspace by an additional 40,000ft² to improve the layout and efficiency of its machine shop and provide more space to accommodate future investments in new technology.