Machine-tool maker optimises manufacturing ability
March 30th 2009 10:41 pm By Web Development in India
Machine-tool builder Boxford has invested in Integrex and VTC 300C-II machines to help keep the manufacture of machine tools for the education market in Halifax for the foreseeable future.
Boxford makes bench-top CNC lathes, machining centres, routers and manual lathes.
Its machine shop was coming under pressure from the variety of work and the relatively small batch-quantities that it was being asked to produce.
Paul Barraclough, director of Boxford, and Steve Randerson, manufacturing manager, visited the UK manufacturing facility of Yamazaki Mazak in Worcester.
The Boxford employees initially wanted an Integrex multi-tasking machine but, after talking it through with Mazak, bought a VTC 300C-II 18.5kW, 12 000 rev/min vertical machining centre.
The employees decided to have the VTC 300C-II fitted with a partition on its 2000mm table, a feature that has eliminated set-up times at Boxford.
Boxford also invested in Mazak’s CPC software and laser tool probing, to allow precise tool-monitoring and management.
Randerson said: ‘Our criteria were to reduce downtime and increase productivity, especially on the small batches that we are called on to machine.
‘The VTC 300C-II has helped us to achieve these aims, with the ability to set one job while another is being machined, eliminating all of our set-up time.
‘A situation helped by the 48-position tool carousel, which is monitored and controlled, along with the sister tools, by the CPC software.’ The VTC 300C-II has allowed Boxford to retire two ten-year-old vertical machining centres, while at the same time increasing productivity and improving component quality.
Having witnessed these improvements, attention returned to the initial plan to install an Integrex multi-tasking machine tool.
Boxford placed an order for an Integrex 200-IV ST, which features standard twin spindles (22kW and 18.5kW), 18.5kW/12 000 rev/min milling and a 120-position automatic tool change, bar feed and workpiece conveyor.
This machine was delivered in December 2008 and will be used to machine a variety of components and operate lights-out on one-off batches.
Randerson added: ‘The versatility that the bar feed, ATC and workpiece conveyor give us is a tremendous boost to productivity.
‘Our plan is to use a single diameter of bar stock to produce a number of components when we run the machine unmanned.
‘While this will result in some wasted material, the cost savings of being able to run lights-out will far outweigh this expense.’ Any components machined overnight will be straightforward chucking jobs that do not require second-end working.
During the manned day-shift, Boxford will use the Integrex’s second spindle to machine more complex components.
The Integrex will allow seven more machines to be taken out of commission, including every manual machine in the factory and the two Mazak machines providing the bulk of the company’s machining capacity for the short-to-medium term.
However, plans are already being developed for the next stage in the investment programme in the machine shop.
Both Paul Barraclough and Steve Randerson are keen to extend the Mazak presence with an additional horizontal machining centre equipped with either a pallet pool or Mazak’s Palletech system.
Barraclough added: ‘We are already witnessing the productivity boost that we expected from the Mazak machines and we are confident that the investment will be paid back on schedule.
‘In terms of productivity, I would say that after capital investment of well over GBP1m in the last few years, we are producing more here now with 50 employees than we did 25 years ago with 120 employees.’.