To cope with increased demand, several European producers have adapted their production processes by duplicating well-functioning production cells. Now that the competition has no borders, production costs are as important as quality.
An alternative to the increase of identical machines pools is to consider new innovative machining solutions, for example with the transfer machines of Mikron Machining. The services offered by this provider help restore competitiveness in European companies while ensuring flawless quality.
The company produces very high precision components in stainless steel for air conditioning systems. The parts to produce (2 x 8 variants) require turning, drilling and deburring operations. Some tolerances are in the order of ± 6 µm with a Cpk = 1.67 and roundness tolerance is 10 µm. the annual volume is 50 + 50 million parts and is growing. At the beginning of the project, the objectives imposed by the customer are a reduction of production costs by 50%, a drastic reduction of waste and the need to increase the volume of production without having to increase floor space.
The goals set by the client have been largely exceeded. Production costs have been reduced by 63.7% and quality of parts has increased. This improvement in productivity is due to the Mikron Multistar CX-24. With 24 stations and 2 units per station, this powerful machine allows machining with 44 spindles simultaneously. The Multistar replaces a large number of traditional machine tools. The flexibility of the system allows it to perform all operations in one clamping and on one machine while simplifying logistics. The quality increase is the consequence of the reduction in the number of machines and operators which influence that point significantly. In addition, the thermal stability and positioning repeatability of the table of the Multistar CX-24 (± 1.5 µm) ensure constant quality production.
We will enter into more details of this success story in our next issue.
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