On some components, CNC sliding-head lathes perform second operations that include two manual milling operations, drilling and deburring eliminating need for extra machines and labour.
Southco UK, Farnham facility, is a world-leading provider of quick access fastening solutions. The company's product range extends to over 14,000 parts with customers including ABB, Boeing, Ducati, Ford, BMW, IBM, Kodak and Sony to name a few. The product range of quick release fasteners, bolt bushings, aircraft receptacle strips, toggle latches and special purpose latches and fasteners is complimented by a capability to providing a multitude of customer solutions.

A capability recently increased by the company's investment in shop floor technology.

The latest acquisitions were two Tornos Deco 20A, 10-axis CNC sliding head Lathes.

The Tornos machines were purchased to free up workshop capacity and provide flexible manufacturing on batches from 1000 to 10,000.

However, the two Deco machines have far exceeded expectations as engineering manager Ben Goater comments: 'The Tornos machines have enabled us take on previously impossible projects'.

'The additional capability, flexibility and speed have now enabled Southco to manufacture complex parts at very competitive prices'.

'Our capability has increased tremendously and labour has been taken out of many processes.' * Productivity benefits - an example of the Deco's speed is demonstrated by a component that previously underwent machining on a six-spindle auto lathe with second and third operations on a (removed M48) special purpose milling machine and a Wurth and Gruffat machine.

The process had a cycle time of 24, 16.5 and 16.5 seconds respectively on each machine totalling 57 seconds per part, prior to heat treatment and plating.

The Tornos machine takes 45 seconds per part eliminating two set-ups; reducing cycle time by 21%, cutting lead times from five weeks to three, and eliminating the need for second operation machines and operating staff.

Goater continues: 'On some components, second operations would include two manual milling operations, drilling and deburring'.

'The Tornos Deco machines have removed second operations and with it the need for machines and labour.' Another example of the benefits could be seen with a product, which previously underwent operations on the six-spindle auto lathe plus manual slotting, milling and drilling machines.

The cycle time for the four machines was 17, 9, 16 and 13 seconds respectively making a combined cycle time of 55 seconds excluding changeovers.

The Tornos now completes all tasks in 35 seconds reducing work-in-progress (WIP - or production inventory) and cycle times by 36%.

This saves three set-ups, ultimately reducing lead times from six to three weeks.

The Southco UK facility in Farnham looked for flexibility and productivity in a machine tool and the ability of the Deco to carry out two milling operations simultaneously provided this as well as significantly cut cycle times for the company.

During investigation, Goater found that competitor machines needed significant modifications to conduct this operation.

Goater says: 'This operation has improved productivity and eliminated problems, especially when machining stainless steel cams'.

'The manual method broke cutters and introduced orientation inconsistencies'.

'The Tornos is 100% accurate and consistent, improving our quality and reducing our tooling costs.' Goater concludes: 'The Tornos machines have been a revelation'.

'The quality of the part is much improved and we can consider materials that we could not machine before'.

'This adds to a plethora of benefits already realised'.

'We hope to have another two or three Tornos machines in the future.'