＃１８
Our proposal example for a short-cycle line that can produce in the early 5 seconds
range per 1 workpiece.

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Case studies
#18　Our proposal example for a short-cycle line that can produce in the early 5 seconds range per 1 workpiece.

#18　
Our proposal example for a short-cycle line that can produce in the early 5 seconds range per 1 workpiece.
Also increasing the productivity per floor space by minimizing
the number of required machines!

Challenges

It would be not efficient for floor space with just increasing the current line...

“We got purchase order with significant increase for the workpieces that we are producing now, but it is difficult for us to ensure the required production volume with our current machines.

In addition, simply expanding the current production line will result in poor floor space efficiency, and if production of other products increases in future, we will not be able to deal with it.

Isn’t there a more efficient production plan?”

Points of the problem faced by the customer

They tried to add more machines to their facilities, but they had no idea how to build a line allowing for high productivity per floor space.

Solutions

In this case, the customer was struggling with a lack of efficient automation methods to significantly increase the production volume.
According to their estimation, they needed three more units of single-axis machines.
After checking their current condition, we found that the times of workpiece loading / unloading on main chucks are taking roughly the same as the machining time, and we estimated that we could make big reduction of the additional machines amount by shortening these idle times.

1 . Machine model selection

While the customer was considering using a robot to load / unload the workpieces, Muratec proposed the ways to improve efficiency by using its gantry loaders.

Among them, we determined that the MW35 CNC Twin-Spindle Turning Machine, which has a dedicated loader for cutting area, was the most suitable for this project.

2 .Idle time reduction

The greatest feature of the MW35 CNC Twin-Spindle Turning Machine is the Swing Loader incorporated in the machine, enabling every workpiece to be loaded / unloaded within 3.7 seconds.

This makes it possible to significantly reduce the idling time.

In order to keep this production speed, we also reduced material transport speed by using a dedicated loader, which handles both raw materials and finished workpieces outside the machine.

Therefore we could achieve both short cycle machining time and high speed transport.

3 . Machining time reduction

In addition to the above-mentioned considerations for shortening idle time, we also conducted additional verification focusing on the way of cutting tool mounting.

At the first time, this customer was considering machines with turret type, but we recommended the MW35 CNC Twin-Spindle Turning Machine uses gang tools.

Because, Muratec’s engineers verified potential for shortening the tool approach and indexing time in order to reduce the machining time itself.

●Comparison of overall cycle time including machining time and idle time

Compared to the “current machine + robot transfer”, the “MW35 CNC Twin-Spindle Turning Machine + Swing Loader” can reduce the cycle time by 50%.

Higher Productivity

By shortening the cycle time and increasing the production volume with a single machine,
the customer has achieved the following results

The required floor space has been saved by approximately 50% compared to the line initially planned.

The amount of machines has been reduced from the three machines (three spindles in total) assumed by the customer,
to one machine (twin-spindle machine).

Product Information

Twin Spindle CNC Chucker MW35

The machine introduced in this case-study is the Twin Spindle CNC Chucker 'MW35'.

■Adaptable to Short-Cycle Workpieces
MW35 is equipped with a gang-type turret, with high acceleration/deceleration spindles, and with loaders for main chuck access / for machine outside transfer to support short cycle workpieces.

■Space-saving and reasonable machine height for good visibility
MW35 is designed with compact height that does not obstruct the line of sight for on-site operators and keeps good visibility.

If you have any questions, please feel free to contact us.

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If you are considering automated production,
please contact Muratec.

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＃１８Our proposal example for a short-cycle line that can produce in the early 5 seconds range per 1 workpiece.

#18 Our proposal example for a short-cycle line that can produce in the early 5 seconds range per 1 workpiece.Also increasing the productivity per floor space by minimizing the number of required machines!