|
 By spinning-off Rodmatic Hytek, a high technology subcontract machining division with a smaller batch capability, from its more traditional volume production operation Rodmatic Multico, Reading based Rodmatic Limited has been able to put a foot firmly in both camps and not only provide a high production solution using the traditional mechanically driven multi-spindle automatic lathe but also a fast turnaround, small batch supply using CNC.
As a result, existing customers have been taking advantage and increasing the size of Rodmatic’s order book for smaller quantities and totally new customers have also been drawn in due to the flexibility of supply for larger volumes of parts and coupled with the ability to react with shorter lead times when needed using CNC.
This has helped managing director Brian Steatham to progressively draw in business that was previously being ferried to low cost production areas overseas. “By adapting and integrating the services provided by the two divisions we now have total flexibility to respond to almost any needs,” he said. Rodmatic Multico, for instance, still runs its 38 mechanically-driven multi-spindle autos, which have capacity up to 80 mm dia, to provide around-the-clock production of something like 1 million parts a month. He now finds the CNC division running through the night as well, but often under unmanned production conditions.
However, moving the business into high technology did not happen overnight. It took careful planning and organisation to transform the way of working and as he was aware of the risk and limitations of the business in trying to achieve the way he wanted it to operate. As a result he put training and retraining as high on the agenda as the commitment to new plant purchase. Reflecting the decision he said: “This has certainly paid-off with batch times being progressively cut to almost half compared to 18 months ago and setting times, cycle times and plant utilisation graphs now bear no comparison.”
He said: “Rather than recruit, we decided to retrain some of our multi-spindle setters and an optical profile grinding (OPG) operator in CNC technology but were very concerned in converting their “spanner twisting” mind set into one of pressing buttons and gazing at screens. However, after the initial trials and tribulations and a steady growth in confidence, they responded in a way we could never have predicted to take on the new responsibilities.”
He follows on to outline how careful retraining in CNC techniques with regular follow up courses with suppliers also created valuable lessons to management in how they were able to read across their traditional skills and adapt their knowledge to bring across new methods and ideas to overcome problems and create further cost savings. He said: “Their biggest initial problem seemed to be to adapt to the new levels of flexibility available from CNC and especially the ability to run faster speeds and feeds and fine tune the setting rather than be restricted due to the configuration and layout of the mechanical machine, and the type of traditional tooling and methods used.”
Over the past three years Rodmatic Hytek has progressively installed a five-axis Daewoo Puma MX 2000ST turn-mill centre, two Daewoo Lynx fixed-head, turn-mill centres and two Star nine and seven –axis sliding head lathes. These are all supported by a programmable via PLC component cleaning centre, a CNC co-ordinate measuring machine, and a programmable non-contact, video-based measuring centre.
The most recent additions to the small batch production area are an Akira Seiki, high speed vertical machining centre with indexing table which is currently being tooled for robotised load and unloading and a Fanuc wire EDM. This machine was originally installed for form tool production run by the OPG operator and is now engaged in production of small batches of complex or high accuracy components.
The retraining for the Star sliding head turn-mill centres with the assistance of Part Maker CAM programming was the most complex maintains Mr Steatham as each setter had to completely rethink his method of working – especially with sub-spindles, balanced cutting cycles and overlapping of tools.
Both latter activities are common on multi-auto set-ups but on sliding head machines it makes a tremendous difference in competitive cycle times. “But there are a multitude of very innovative practices and process dodges built-up over the years by the setters which he defines as ‘the skills’ behind making a multi-auto really productive. It is this skill base that has now been introduced very successfully to our CNC operations on higher value components,” he said.
“We now supply a much wider group of customers with a lot of complex parts in batches that range for a few dozen to several thousand. The difference is these now involve extensive changeovers and new challenges,” said Mr Steatham. “It is the number of resets that keep the setters on their toes and creates for them totally new levels of interest having to agree plans with production control on a regular basis to achieve the best use of machines, materials and tools,” he added.
The single cycle philosophy now involves a considerable amount of milling, totally different materials from mild steel which now include a whole raft of stainless steels and materials such as EN 24T. Prior to setting up Rodmatic Hytek, most parts leaving the factory were only turned from mild steel and parts requiring special features to be machined such as drilling, milling and grinding were performed on conventional or special purpose equipment depending on the quantities involved.
With the constant demand for re-setting machines at Rodmatic Hytek, regular training updates with machine and tooling suppliers has been the key to keeping up with technology, developments and techniques. Said Mr Steatham: “Not only are we finding that we are attracting new customers, we are significantly increasing the rate of converting enquiries into orders, which gives a huge boost in confidence and confirms to everyone involved we are on the right path.”
|
