Changing the Culture of a Shop

Adding a multitasking machine to the shop floor can be a daunting task … but also a game changer

Multitasking equipment

Multitasking equipment can perform machining tasks such as pinch (balanced) cutting where two tools cut simultaneously. Photo courtesy of Mazak Corp.

Thanks to live tooling, the concept of adding milling capability to a turning center is decades old. Live tooling stations give manufacturers the ability to perform certain milling, drilling, and other machining tasks within the work envelope of a lathe.

Today, however, the theory of multitasking takes this simple idea into new and complex areas. Simultaneous turning, multisided machining, automation, and large-capacity automatic tool changers have given these machines the ability to perform even the most complex of machining tasks and finish a part completely in a single setup.

No longer are these machines either a lathe with a milling option or a mill with a turning option. Rather, they are hybrid machines of a new type: a multitasking machine.

Multitasking machining can drastically alter a shop’s work flow -- and culture -- while reducing per-part costs and improving quality.

According to David Fischer, lathe product specialist for Okuma America Corp., multitasking machines can have a dramatic effect in several ways, including an elimination of setups and setup time, a reduction in cost per part, and an improvement in overall productivity and part quality.

“Shops should consider the overall impact a multitasking machine can have on their business as a whole, and not just look at a particular part or family of parts. While the impact on one part can be significant, the impact on the business can be dramatic, even shocking,” said Fischer.

The operating costs of using multiple conventional single-purpose machines in terms of labor, fixturing, tooling, electrical consumption, and floor space will be higher than those experienced when using a multitasking machine. However, the downside is that if a shop relies solely on a single machine and it goes down, the entire part-production process stops.

Reimagine Your Parts

Parts can even be designed in a better way thanks to this new technology. And accuracy can be maintained better on a single machine versus multiple setups across multiple machines.

“People often look at multitasking machines simply as machines that combine conventional processes,” said Chuck Birkle, vice president of marketing - Cybertec Division for Mazak Corp. “A different way of thinking is that these machines can now create parts in an entirely new manner that is not possible on other equipment.”

Turrets and Spindle

Multiple spindle and multiple turrets enable multiple parts to be created simultaneously. Photo courtesy of Mazak Corp.

The complex movement inside the machine, combined with multiple turret/multiple spindle machine setups, enables the most complex parts to be machined, a situation that is beneficial to shops competing against the global supply chain.

“Shops that want to differentiate themselves can use multitasking machines to create complex parts efficiently,” said Birkle. “This allows North American manufacturers to reshore high-value work and currently is quite evident in Canada in several geographic locations. In the west, multitasking equipment is being used to produce large, complex workpieces for the oilfield. In Ontario the job shops are using this equipment to serve many different industries, including the medical industry. And in Quebec, these machines are very popular in the aerospace sector. It’s like having three separate multitasking hotspots.”

With so many options available today, how can a shop decide on its needs?

“Ideally, the machine will excel at both turning and milling operations,” said Fischer. “There are machines on the market today that can perform turning tasks that are normally seen in a large-bore lathe and the milling tasks in a large horizontal machining center.”

Determining the options necessary when buying a multitasking machine often goes beyond whether the part is cylindrical or prismatic. Many cylindrical parts are created on multitasking machines, but they typically are large-diameter parts.

“Large parts are great examples of work that is returning to North America,” said Birkle. “Parts that are difficult to move are best created close to where they are needed, and shops that can do this work are the ones that are going to be successful in the coming years.”

The decision on the type of multitasking machine that is best for a shop should be made following a review of both current and future machining needs.

Mazak has divided its multitasking machines into five levels, from the most simple to the most complex, but no matter the level, options, or power, an examination of common parts is a good place to start.

“We ask our customers about their workpiece size, volumes, and complexity to help decide on the machine,” said Birkle. “Each customer’s parts are unique to their shop, and the solution to their machining problems also may be unique.”

After Installation

Hybrid multitasking machine

These machines are no longer simply a lathe with a milling option or a mill with a turning option. Rather, they are hybrid machines of a new type: a multitasking machine. Photo courtesy of Okuma America Corp.

Once the machine hits the shop floor it needs to start producing parts. It is essential that the shop’s designers, programmers, and operators all are familiar with the machine.

“Training is very important for all machines, but even more so with multitasking machines,” said Fischer. “There can be a lot of moving parts inside these machines, and it’s important to understand how they operate.”

Part simulation also is an important step.

“A multitasking machine can be a significant investment for a job shop, so it’s always a better idea to crash the machine in the virtual world than in the real world,” said Birkle.

Essentially it all comes down to the bottom line. These machines can make a shop money. Work can be finished faster, shortening the billing cycle and improving cash flow. However, shops need to be ready to experience a culture change, and a change in the way they think about creating parts.

www.mazakusa.com

www.okuma.com