Manufacturing from Order Entry to Invoice

Process Flow and Robotics are Formulas for Partners in THINC Success at IMTS

With a premiere booth and concept at IMTS 08, Partners in THINC reproduced a full manufacturing facility in a mere 4,800 sq. ft. of space, producing a model air-cooled engine assembled and boxed for shipping by robots.

Not only did the cell demonstrate a vast number of equipment capabilities from Okuma and more than 20 participating Partners, but most importantly, it showcased process flow - complete from order entry to shipment invoicing - all through the THINC control.

In a nutshell, six different cells produced a total of 10 parts in a cycle time of approximately 33 minutes. Though a manufacturing engineer collected the individual parts from each machine to take to the robots to assemble due to space restrictions in the booth, this process could be automated by parts catchers, automated guided vehicles and/or conveyors according to Jeff Estes, Director of Partners in THINC.

"It takes about 17 minutes for the two FANUC robots to assemble the motor and package it," said Estes. "This includes thorough inspection of every component by the FANUC vision system, including fasteners, and then putting the completed product into a box. Now, human hands do actually close the box, insert the packing list and the invoice generated by SAP and/or JobBoss - we're using both - and then the pre-printed FED-EX label is applied. This process could also be automated with further investment into available packaging and shipping systems - I'm thinking about $30,000. We just didn't have the space at IMTS to do this."

Partners in THINC and the Power of THINC
The concept of Partners in THINC is built upon the Okuma THINC control (THe, Intelligent Numeric Control), an open architecture, Microsoft Windows-based platform, and how more than 30 Partners collaborate through the Charlotte, NC facility to bring out the best of the control's capabilities for their advanced manufacturing customers.

"The THINC control is Ethernet-ready and offers plug-and-play compatibility to Okuma machine tools and industry peripherals required in manufacturing," said Estes. "The control is designed to optimize productivity through the availability and adaptability of real-time information for our end-users."

Taking the process and capabilities of Partners in THINC to the next level and showcasing the collective strengths at IMTS was the vision of the Okuma America Corporation Engineering group.

"The vision of the Partners in THINC Booth is simple," said Brian Sides, Director of Engineering for Okuma America Corporation. "For the first time ever, collaborating Partners are presenting our customers with a real factory setting within a trade show setting - right down to not having carpet - which demonstrates the reality of business, automation, and quality systems connecting and communicating to provide productivity improvements and real time visibility of the manufacturing process from order entry through finished goods shipment."

Connectivity
The THINC control is compatible with SAP Manufacturing Integration and Intelligence (SAP MII) platform creating "seamless connectivity" between all machines and systems without additional engineering required, according to Bryan Newman, Director of Information Systems at Okuma America Corporation.

"SAP MII is an example of a perfect match for making Okuma machine tools the most efficient and adaptable on the market," explains Newman. "Customers can get a unified view of manufacturing data through synchronized manufacturing operations and back-end business systems. Being able to access data and analyze opens up opportunities for greater efficiency and mitigates operational risk."

Exact Software's JobBoss program is also used to demonstrate an alternative for an ERP system - a lower cost option to SAP MII.

"Exact understands the competitive pressures job shops face in learning how to maximize business performance by bringing together seemingly unrelated processes into a cohesive system to build their shops more effectively," said Newman.

Equipment Integration
With the Okuma machine tools and THINC control at the center of each cell of this simulated manufacturing facility at IMTS, Partners who demonstrated include: Marposs, Exact JobBoss, Midaco, ISCAR, Sandvik Coromant, ABB Robotics, Kennametal, Gosiger Automation, LNS Turbo, Shell Lubricants, Renishaw, FANUC Robotics, Caron Engineering, SAP, Schunk, Royal Products, Blum, Extrude Hone, BigFix, Symantec, Trend Micro, WebEx, ChipBLASTER, Zoller, IEMCA, and Infinity Rebuild.

Highlights of the Partners in THINC booth include a process that begins with the MB56-VA that produces the head and connecting rod on the 3-axis vertical machining center. A Midaco pallet changer is utilized to maximize spindle cutting time and Renishaw On Machine Verification (OMV) software and probing systems are utilized for quality assurance. The ChipBLASTER high pressure/high volume coolant system ensures high production and thorough chip removal. The Extrude Hone ECM CoolPulse proceses unwanted material without harmful, corrosive compounds on the head component.

The engine case and cylinder were machined complete on the 4-axis HMC MA-400H with a Fastem container system that demonstrated the ability to load multiple jobs onto the cell with almost zero change-over time from one part to another. Marposs provides 3DSI, CAT40 Probe and Quick SPC software that are compatible with the THINC control. In addition, there are two choices for tool management systems.

"If a system like this was purchased, the customer would have a choice between the ISCAR Matrix or Kennametal ToolBoss tool management systems which are shown here at IMTS," said Estes. "They are both compatible with the THINC control and the Zoller presetter. It's just a matter of the customer's preference, and we want to give them options."

A timing pulley was machined complete on the 4-axis LU-400M lathe with milling function turret. The IEMCA bar fed material extends unattended operation while the Marposs post-process Bluetooth gauging ensures part compliance. Caron Engineering's AutoComp software automatically controlling tool offsets and tracks toolwear. The Twin Millac 33T machine cell utilizes multi-function vertical machines to complete the Op 10 / Op 20 piston. An ABB robot loads, transfers and unloads to and from both machines through special automated doors integrated by Gosiger Automation. Both Sandvik Coromant (tooling) and Kennametal (tooling and rotating tools) are used for metal removal.

The crankshaft and the spark plug are produced on the LT-200MY through integration of the Gosiger Automation slider system with FANUC Robot which will load/unload the crankshaft while the spark plug is bar-fed by the LNS barfeeder. Caron TMAC7, a tool monitoring adaptive control application created by Caron Engineering, monitors spindle horsepower in real time during the cutting cycle. It is capable of dynamically adjusting axes feed-rate to maintain an optimum torque curve for each cut, thus maximizing tool life, minimizing cycle with the ability to monitor coolant flow to insure steady tool load through each pass.

The display base for the model engine was machined on a re-furbished LC-40, 4-axis lathe from Infinity Rebuild that was originally manufactured more than 20 years ago. The LC-40 was upgraded with a THINC OSP-P200 control, making it more compatible with the refurbished ABB robotics cell and the entire ERP system. Trumpf laser marking was used to add logos to the base (and a serial number to the piston), but can be used for any marking requirements on metal surfaces according to the manufacturer.

Assemble and Ship
Two FANUC robots, integrated by FANUC robotics, assemble all the components manufactured in the Partners in THINC booth to complete the model air-cooled motor and package it for shipping. Customers who registered to win were randomly selected to receive units produced daily by swiping their IMTS badges at eight or more Partner booths who featured the THINC control simulator, all linked via internet according to Sides.

"We are shipping finished motor assemblies daily from the Partners in THINC booth per a production and assembly schedule for customers who place orders generated by visiting our participating Partners' booths," Sides says.

"Pulling this together within a trade show environment is a testament to the power of collaboration of Partners in THINC made possible by the intelligence and openness of the OKUMA THINC control," he adds.