Both WorkNC and WorkNC-CAD are used on the shop floor at Brandstatter, bringing autonomy to the users who also operate the machine tools.
Children and parents around the world are familiar with the popular Playmobil toy figures. The Brandstatter Group, the company behind the brand, has its headquarters in Zirndorf near Nuremberg, manufacturing facilities in Dietenhofen, Germany, and overseas production in Malta, Spain and the Czech Republic as well as Playmobil subsidiaries in 11 countries. The company can trace its roots back to 1876, when it began manufacturing cabinet fittings and locks, before moving into toy manufacture in 1921.

Horst Brandstatter, the current sole owner recognised the threat of competition from low-price economies at the beginning of the 1970s and so initiated the development of a new range of toys.

This led to the launch of Playmobil, small moveable plastic figures with matching accessories.

Since 1974 nearly 1.9 billion have been produced.

The Playmobil brand's rapid success was remarkable, and Brandstatter has become the largest toy manufacturer in Germany, with a 2005 turnover of Eur 377 million.

Quality and innovation are important factors in the brand.

Reiner Merkel, Head of Mouldmaking at Zirndorf, said: 'Playmobil figures do not break and lose their attractiveness'.

'Therefore our products are not thrown away, but tend to be kept for the next generation'.

'The various product ranges are carefully co-ordinated so that the figures go together well'.

'There is now a considerable collectors market for them, which contributes to their success', added Gerhard Ammon, Mouldmaking team leader.

Time is a major factor for the production of new Playmobil figures, which need to match current topical themes such as the football World Cup, making mould design and construction of major importance.

Merkel said: 'Over the last ten years the throughput time at Playmobil has been drastically reduced'.

'Whereas we used to produce one new product line per year, now it's five or six'.

'We manufacture up to four new moulds each week'.

'This is only possible because we use the latest tools, including powerful 3D-CAD and CAM systems'.

Brandstatter's existing CAM system could not keep up with the increase in demand, and its lack of machining strategies forced the company's engineers to programme manually, leading to errors and delays on the machine tool.

Following a WorkNC demonstration, Gerhard Ammon commented: ' It opened up new possibilities allowing us to achieve more than we had ever anticipated'.

'Ease of use has resulted in faster training, and we have succeeded in greatly increasing our electrode production rates using the software'.

'An additional big plus for us is the stability and reliability of WorkNC'.

Both WorkNC and WorkNC-CAD are used on the shop floor at Brandstatter, bringing autonomy to the users who also operate the machine tools.

Jurgen Holler one of the users explained: 'With error free 3D CAD data, the machining strategies are applied and the calculation started - that's it'.

He continued: 'Through the combination of the simple programme operation with the intelligent processing strategies, a high level of accuracy is guaranteed, enabling us to minimise costly errors in our CNC programs'.

The automatic features in WorkNC save effort, while giving the operator more time and the flexibility to respond to the special circumstances which arise in some of the company's more complex tools.

WorkNC-CAD has also had a major impact on productivity.

By importing the IGES file the programmer is able to check for model integrity.

If the model needs repair or closing, functions inside WorkNC-CAD allow this to be completed with a few mouse clicks.

Previously this task had to be referred back to the design department, adding to its workload, and causing delays in the two shift system operated in the workshop.

Holler added: 'Frequently, we used to have to wait until the next day to have a model repaired'.

'This bottleneck, which had huge time-loss consequences, no longer happens'.

'Since the introduction of WorkNC-CAD we have not had a single case where we could not take remedial action ourselves'.

Other WorkNC features which are particularly valued by the company include the automatic production of HTML workshop documentation which allows clear communication between shifts, and the tool and toolholder libraries which keep track of available cutters.

Ammon said: 'Using WorkNC on the shop floor makes sense, as the machine operator understands the important elements of setting and operating the machining centres, so he is in the best position to optimise the performance of WorkNC'.

Ten years after the decision to purchase WorkNC from Sescoi, the Playmobil managers see it as the best decision that they could have taken for machining.

'The software is worth its weight in gold', said Ammon.

'Many processes are easier thanks to WorkNC'.

'It paid for itself in less than a year'.

He concluded: 'The calculation is easy - today two WorkNC workstations ensure that five work machines are in use simultaneously'.

'That's what I call productivity'.

Delcam USA will demonstrate new toolpath editing functions within FeatureCAM Version 2007 on Booth D-3228 at IMTS in Chicago, from 6th to 13th September 2006. The increased ability to make edits to the automatically generated toolpaths can reduce cycle time on the machine. In many cases, even a few minor changes can save significant amounts of time when production machining large runs of parts.

With toolpath editing, users can make changes to part toolpaths after they have been generated, without needing to retrace their programming steps back to the feature setup.

Users simply click on the section of the toolpath they want to edit and indicate the desired change.

Examples of edits include changing a rapid move to a linear feed move, changing a linear move to an arc, setting or changing the feed rate, deleting a move, inserting a toolpath from another operation, reversing the path, combining two moves into a single move, as well as several other options.

Tom McCollough, Vice President of FeatureCAM Software Development, explains: 'We work very hard to make a product that is easy to use by novices and infrequent users, yet with the all the power needed for advanced part programming'.

'For us, powerful means the ability to control the product to do exactly what the customer needs it to do while utilising advanced technology to free the user of the burden to specify obvious manufacturing information and techniques'.

'FeatureCAM has long been a leader in CADCAM automation'.

'With the addition of our new toolpath editing functions, we have extended the range of options that provide precise control for our customers'.

Leif Andreasson drove his ESAB backed 3500bhp Dodge Stratus styled dragster to a clear victory at the opening event of the 2006 European Drag Racing Championship Funny Car series at Santa Pod, Northamptonshire, UK, recently. His victory in the Top Methanol Funny Car series came to the delight of major sponsor ESAB, the global welding and cutting equipment and supplies group, which has been supporting the Andreasson team over the past four years. Despite intermittent high winds and showers throughout the weekend, Andreasson eventually won the series by clinching the finals title from fellow Swede Ulf Leanders' Firebird with a 5.77 seconds run against Leanders' 5.93 seconds.

The result gave Leif an average 245 mile/h over the quarter mile and was the fastest time for the event.

'This is a fantastic result', said Andreasson speaking after the awards.

'We've been troubled with tyre shake and other irritating issues for eighteen months, but now everything has come together just fine'.

'The car ran perfectly'.

'I have to thank my whole team for that'.

Earlier in the day at the semis, Andreasson had come up against Jurgen Nagel, but despite a performance drop due to cracked isolators in the spark plugs, he managed to see off the German to earn his place in the finals and eventually go on to win the event.

The Andreasson Team's entered the 2006 with an entirely new image with both car and driver fully bedecked in military camouflage.

This new look came as a result of additional backing from the Swedish Armed Forces.

However, even with the camouflage, ESAB retained its highly prominent exposure down the rear sides of the car along with fellow top sponsor Kamasa Tools.

There is nothing funny when it comes to the engineering behind these Funny Car Series competitors.

The statistics attached to these cars are nothing short of awesome.

The top methanol fuelled BAE 8528cm3 V8 aluminium/magnesium engine with PSI supercharger develops some 3500bhp at up to 10,500rev/min and there are no engine cooling cavities, coolant or radiator.

The chassis beneath the Dodge Stratus styled carbon fibre body is precision engineered in cromemolybden steel tube using ESAB advanced welding technology.

Visitors to the NC Engineering stand at MACH 2006 will not only be able to see demonstrations that improve productivity when using the latest developments in CNC sliding head mill/turn technology but also take part in a free draw for two VIP tickets to the Wimbledon Tennis Championships, the most prestigious tennis event in the world staged in June at the All England Lawn Tennis Club. While five new machines and the latest Streamline machining technology are being demonstrated on the stand, there are additional features being shown to help users of citizen machines improve their productivity as well as reducing production costs per part. For instance, NC Engineering will preview a new quick change tool system developed exclusively for Citizen machines by Sandvik Coromant with Citizen in Japan.

There will be a new generation Coolblaster 2000 lb/in2 high pressure coolant system, a finished component collector that will segregate parts for inspection and a totally new CNC wizard that is 70 per cent quicker to use than a normal cam programming system.

The 'New at MACH' Citizen machines include a 12 mm and 16mm capacity low cost K-Series with 19 tools of which eight are driven, the latest L20-VIII with 21 tools and nine driven and through Streamline Technology provide savings up to 50 per cent on non-cutting times.

From Citizen Boley the latest fixed head BE42Y with twin turrets, Y-axis crossfeed, 25 tools of which 15 are driven and three tool simultaneous cutting will be demonstrated as well as the high precision linear drive Citizen RO7 having 10 tools and three driven tools.

The Sandvik quick change tooling system designated QS for Quick Start is dedicated to Citizen machines.

Visitors will be able to appreciate a change of tool that can be made in just 20s.

The new compact CoolBlaster III - a very popular option for swarf control and improved cutting performance - now has a low energy, continuous and quieter pump operation.

It has a 10 feed point option to the standard five outlet and is so compact it will fit under the bar feed of the machine saving valuable floor space.

The top of the range and best selling machine in the UK, the Citizen M32-V with two Y-axis slides and programmable auto unload, will also be demonstrating a novel rotary parts collector that can be set to isolate a required ratio of parts for patrol inspection and from Citizen's software team, a newly developed citizen cnc wizard programming aid will be launched.

This Wizard will be demonstrated to further simplify programming routines by some 70% using a series of macros with prompts to fill in the missing information.

The software is available from NC Engineering at a fraction of the price of a conventional CAM system.

At MACH 2006, a producer of standard machine components and mechanical machine indicators offers a way to reduce set-up time and improve productivity on multi-spindle automatics.
Elesa - for many years now an innovative leader in standard machine components and mechanical machine indicators - has brought their understanding of customer needs to Mach 2006. This takes the form of a way to reduce set-up time and significantly improve productivity on multi-spindle machines requiring frequent resetting. Their new Electronic positioning system includes its own programmable controller or can function with the machine's own PLC.

This allows the operator to see at a glance which shafts are in correct position and to then select new rotational ratios for shaft travel, etc Along with this exciting time/cost saving development for production and retro-fit applications, there are new ranges of hinges, latch clamps and grab handles.

These both complement existing ranges and extend performance/usability for anyone looking to source quality standard components as product solutions for new build or upgrade projects.

'Streamline Machining' depicts the benefits achieved from the new control system, software and mechanical developments resulting in up to 40 per cent faster machining cycles.
Streamline Machining' is a new term adopted by Citizen for its latest generation of CNC sliding head turn/mill centres that depicts the benefits achieved from the new control system, software and mechanical developments resulting in up to 40 per cent faster machining cycles than could be achieved using the same program and tooling on the previous generation machines. At MACH 2006 on NC Engineering Stand 5262, the latest L20-VIII and K12 and K16 citizen machines will be demonstrating the benefits of these new levels of flexibility and the ability to cut with two tools simultaneously at the main and subspindle involving single 'one-hit' cycles. Central to streamline machining is the Citizen software development for the new control systems.

The low-cost Citizen K12 and K16 machines have a special version of the latest Fanuc 31i Series control and the L20-VIII an advanced Mitsubishi 700 control.

Both the K and L ranges can perform with the involvement of up to five-axes with full synchronisation of the main and subspindles, direct spindle indexing that is able to pre-select the reference point of the C-axes even while the spindle decelerates.

This saves valuable time against the previous generation control operating routines that required the spindle to be stationary before the protocol sequence could seek the reference point.

What has to be considered is that many of the Citizen cycles used at customers involve considerable C-axis spindle positioning for cross drilling and milling.

Both machine types have had rapid traverse rates increased by 60 per cent to 32 m/min with the added advantage that acceleration and deceleration rates are improved by a factor of 1.6 on each axis.

By utilising the new shockless acceleration/deceleration curves, each machine is now able to give greater machining consistency with extended tool life and improved levels of surface finish.

Also, as a tool enters a cut, it is now able to overlap with the exiting tool that once again saves non-productive time and reduces any likelihood of vibration or pick-up on a machined surface as the new tool engages with the workpiece.

A further significant factor is idle time reduction on the new machines, especially when thread cutting and tool changing.

Here, the ability of the control to read ahead, enables the pre-emption of simultaneous axis movements.

The Citizen L20-VIII with a 20 mm capacity by 200 mm machining length can carry up to 21 tools with nine driven.

In recent trials a 240 second machining cycle was reduced to 164 secs - a 29 per cent saving.

At a UK customer, Unicut Precision of Welwyn Garden City, an L20-VIII was able to reduce cycle times against a previous L20 installed in the works, by almost a third.

The K12/K16 with 12 mm (1/2 inch) and 16 mm capacity will carry 19 tools with eight driven and compared to the B12 Citizen machine replaced at Tenable Screw of Merton, a K16-VII was able to reduce the cycle time on one part from 55 secs to 36 secs, a 35 per cent saving on each part produced.

Specialised fastener manufacturer's CNC sliding-head automatic lathe is slashing production times and providing the capability to quote same-day order turnaround if necessary.
One of the UK's leading subcontract manufacturers of specialised fasteners and other turned parts, Vaughan Jones in Wetherby, Yorkshire, has invested in a third Star sliding-headstock lathe to extend its pursuit of one-hit machining to components of up to 32mm diameter. The Star SV-32 lathe has taken over from fixed-head turning of complex parts, slashing production times and providing the capability to quote same-day order turnaround if necessary. Vaughan Jones' joint managing director, Roger McGlone, cited the case of a typical socket screw which previously required five separate operations: blank and turn roll thread diameter; face, centre and drill; broach; clear broach chips from the bottom of the socket; and thread-cut or roll.

The accumulated cycle time total was between 4 and 8 minutes, depending on component size, and lead time from order to delivery used to be one month.

The same job is now completed in one visit to the twin-spindle, multi-axis Star SV-32 in a cycle time of 1.5 to 2 minutes and additional operations such as head drilling can also be carried out in-cycle.

Not only is immediate turnaround of urgent orders possible, but economic batch size is also reduced and so too is the amount of work-in-progress (production inventory) on the shop floor.

Vaughan Jones started its investment in sliding-headstock machines in 2001 with the installation of a Star SR-20R lathe of 20mm bar capacity, followed in 2003 by a second, identical machine.

Continued Hornby, 'We had one hundred or so cam autos and plug-board machines operating 10 hours a day and basically we were getting nowhere.

We decided on a rolling programme of replacing these outdated lathes with sliding-headstock CNC models, having satisfied ourselves that this was the way forward rather than going along the fixed-head route, which would have curtailed our one-hit machining strategy.

Very few of our components need a second operation now.

Hornby said: 'The other considerable benefit of installing the Stars was the advent of year-round 24h operation, trebling available hours compared with a manually-operated auto.

Moreover, the majority of productive hours on a Star are minimally manned, resulting in labour cost savings as well.' The latest Star SV-32 has the capability to deploy 80 tools in the working area whereas even with diversification into more complex parts such as bar-turned nuts and couplings, only six or seven tools are currently used to produce any particular component.

Likewise, the capability of the Star to produce special features such as off-centre and angled holes around the circumference or in the end face of a component are scarcely used.

Hornby's reason for installing this machine was, however, not only to expand Vaughan Jones' fastener range but also to diversify into the subcontract production of more complex parts, a service which he is actively marketing both within and outside his customer base.

Materials vary widely and are often difficult to machine, hence the addition of high-pressure coolant to the latest Star lathe.

They include high-tensile, stainless and mild steels, brass, bronze and nickel alloys as well as aircraft materials and plastics.

Manufactured to international standards and customers' specifications, Vaughan Jones' high quality products find their way into diverse industries including defence, aerospace, mining, medical, telecommunications, machine tools, tooling, motorsport and automotive engineering.

Using linear motors to remove any likelihood of deflection and backlash from the power transmission system a very compact sliding head automatic offers super precision with high speed.
By using linear motor technology to remove any likelihood of deflection and backlash from the power transmission system and to optimise the structure of the slideway, Citizen has been able to create a very compact machine able to capitalise on combining super precision with high speed one-hit machining cycles and short cycle times on components up to 7mm diameter by 40mm long. As a result, the new Citizen R07 Type VI CNC sliding head auto is reckoned to be significantly faster than a traditional cam auto when machining parts in single cycles using the main and subspindle and up to 13 tools while maintaining a very compact footprint when installed on the shopfloor. The Citizen R07, launched in the UK by NC Engineering of Watford, UK, has no hydraulics or pneumatics and is totally electric and electronic in operation.

It has six axes, a 16,000 rev/min, 1.1kW built-in main spindle with ceramic bearings for optimised machining of small diameter parts and a 0.5kW secondary spindle with an 8,000 rev/min capability.

Having two independent toolposts able to hold 13 tools, of which two are driven by 0.2kW, 8.000 rev/min spindle, two tools are able to simultaneously machine a component.

An important development with the RO7, that significantly increases machine utilisation, is the ability to open and close the collet at normal machining revolutions without having to slow the spindle.

Accuracy is high with increments of 0.0001mm in each axis and repeatability of one micron is possible.

By combining linear drive technology to both tool posts, high productivity is guaranteed with rapid acceleration to maximum traverse rates of 20m/min.

The maximum machining length is 40mm and with the two slide arrangement, five turning tools can be mounted on the gang tool post with two cross-driven tool positions.

In addition, three end working tools can be applied to each of the main and secondary spindles to high orders of positioning accuracy through the use of glass scale encoders.

Drilling and tapping capacity at the main spindle is 4mm and M3 respectively with 2mm and M2.6 for the secondary spindle.

Driven tool a capacity is 2mm.

The main spindle has 1 deg indexing and both spindles have rotational synchronisation for part transfer.

There are a number of canned cycles for polygon turning, thread cutting, drilling and rigid tapping and constant surface speed is standard.

Obtaining the maximum productivity from 'single-cycle' mill/turning applications on CNC sliding head automatic lathe was the theme set by NC Engineering at its 2005 Open House.
Obtaining the maximum productivity from 'single-cycle' mill/turning applications for CNC sliding head auto produced components up to 32mm diameter and fixed head mill/turn centres up to 42mm capacity, was the theme set by NC Engineering for its Open House staged at its Bushey, Watford, UK. showroom in October 2005. Joined by leading tooling specialist Sandvik Coromant, demonstrating a new range of tooling at the event, NC Engineering showed under power for the first time in the UK, the production advantages available from three new machine developments by Citizen.

The two new sliding head machines, the high precision and fast cycling RO7 employing linear drive technology and the latest M16-V which, like the larger capacity M32, now employs a second Y-axis to the turret as well as the tool slide, provides a massive leap in flexibility for setting and shortening cycle times.

From the fixed head stable of Citizen Boley, the new BE 42 also brings many of the advantages and common elements of world-leading sliding head technology from Citizen to fixed head machining for parts up to 42mm diameter, using the main and subspindle and its twin, driven tool turrets.

Talking productivity increases is one thing - proving and quantifying the benefits is another and here, NC Engineering and Sandvik Coromant have had extensive successes at Citizen users generating huge savings from joint application development.

A recent prime example was at Monument Tools of Hackbridge, Surrey, UK, where two new Citizen M32 CNC sliding head machines replaced fixed head lathes and milling machines creating savings up to a massive 60%.

In addition, lead times have been significantly reduced by combining up to five separate operations into one with NC Engineering and Sandvik Coromant developing a special polygon turning process resulting in the reduction in cost of cutting tool inserts from GBP 45 to just GBP 3.

Also by switching to thinner CoroCut 1.5mm wide parting inserts consumption of steel bar has been reduced by a 1000m on a particular job.

Indeed, at the Open House, Sandvik Coromant demonstrated its new CoroCut MB (minibar) boring concept for grooving, turning and threading holes over 10mm diameter.

Also presented was CoroCut XS (extra small) for smaller bores down to 1mm diameter.

A new range of Delta C drills between 0.3 and 1.4mm.

Alongside the new citizen machines were the latest K-Series CNC sliding head auto in 12mm and 16mm capacities and the all new Citizen L20.

The first UK installation of two L20 machines in the UK at Unicut Precision have already enabled floor to floor times to be cut by up to 30% due to faster processing and dramatic reductions in idle times.

Says Jason Nicholson joint managing director: 'Some of these cycles are equal to cam autos, but with far greater consistency and accuracy.

Latest CNC sliding head turning centres - including one that guarantees a degree of precision of +/-1 micron - brought a 24% increase in MACH visitors to a Swiss machine tool builder's stand.
MACH 2006 was the first opportunity for Tornos to present two exceptional new machines to the UK. The Swiss sliding head turning centre specialist presented the new Tornos Deco 8sp and the Deco 20s - the first machines of the new S-line range. The new innovations from the sliding head lathe manufacturer brought a 24% increase in visitor numbers to the stand compared to MACH 2004.

More impressive was the fact that 67% of visitors to the Tornos stand were potential new customers.

This extremely high number of new contacts is testament to the market research and product development that has been conducted by Tornos.

This research has enabled the company to develop exciting new products that have grasped the attention manufacturers from new market sectors.

The first machine launched in the new S-Line range, the Deco 8sp is world's first 10mm capacity single-spindle CNC sliding head lathe without guidebush.

With five linear axes, the Deco 8sp provides an excellent price-to-performance ratio whilst the kinematics have been adapted to execute reasonably complex parts.

It is a technological solution that allows Tornos to offer an automatic lathe that guarantees a degree of precision of +/-1 micron (0.001mm) never seen before.

The Tornos 8sp addresses new markets such as the electronics and especially the hard mini-disk sector for mobile IT applications The second machine launch at MACH 2006 was the Deco 20s, which is designed to execute relatively complex parts up to 25.4mm diameter.

The programming and kinematics of the Deco 20s are geared towards simplicity, which is coupled with strong mechanical elements to guarantee high precision.

With six linear axes, the 20s has been designed for producing reasonably complex parts with an excellent price-to-potential ratio.

The considerable strength and power provide the lathe with a very large machining capacity.

Another important aspect is its versatility - the machine has 22 tool positions and a high level of interchangeability to give the Deco 20s exceptional flexibility.

Numerous market studies were conducted and the Deco 20s is the resulting machine that is well suited for the automotive, medical, electronics and connector and general manufacturing sectors.

This was demonstrated with the visitor figures at the MACH 2006 show - 20% of visitors to the Tornos stand worked in the automotive sector whilst 22% were involved in the aerospace industry and another 11% in the connector and electronic markets.

The third machine that appeared on the stand was the Deco 26a 10 axis turning centre.

This proven technology was also very well received at the exhibition and the combination of the three machines manufacturing components on the stand for various industry sectors enabled Tornos to demonstrate its expertise and capabilities.

Stainless steel plug shells for connectors are being machined 30% on a twin-spindle CNC sliding-head lathe followed by a single shaping operation - eventually to be incorporated in the cycle.
Stainless steel plug shells for aerospace connectors are traditionally produced by Doughty Precision Engineering (DPE) in three operations, one on a fixed-head lathe and two on a gear shaper. Now the same component is machined 30% faster on a twin-spindle Star SV-32 sliding-head lathe followed by a single shaping operation. The time saving will not end there.

In the same way that DPE and Star initially developed a special hobbing attachment that transferred machining of the shell's ratchet teeth to the SV-32, the Nottingham, UK-based subcontractor and the machine supplier are now working together on another attachment that will allow the slider to complete the remainder of the shaping, i e, machining of the alignment teeth.

In other words, a part that used to require transfer from one of three fixed-head, 3-axis bar lathes to one of five gear shapers for two additional operations, will in future come off the Star complete.

This will allow one operator to be deployed on different work, reducing still further the already substantially lowered cost of producing plug shells.

Said Peter Doughty, 'Early sliders were able to reduce the original fixed-head, mill-turn cycle by only 20s, so we could not justify the investment.' He continued: 'In contrast, the 9-axis SV-32 has cut approximately one minute out of the mill-turning, which includes threading, boring, reaming, slotting and broaching.

This is because we get a lot of machining for free by working on a part in the counter spindle while simultaneously machining the next component at the main spindle.' Doughty said: 'We have also got rid of one handling operation by incorporating on the lathe the cycle to shape the ratchet teeth.

When we transfer alignment key shaping onto the Star later this year, we will eliminate inter-operation handling altogether.' DPE will eventually use the Star, which is fed by an FMB Turbo bar magazine, to produce 10 sizes and varieties of 303, 304 and 316 stainless steel plug shell up to 32mm diameter.

They account for 40% of the total, as shells go up to 50mm diameter.

Batch size is typically 5,000-off.

Doughty intends to maximise his company's use of sliding-head technology, pointing out a number of benefits over fixed-head mill-turn centres.

One often-overlooked advantage is that a slider typically draws less than half the power of an equivalently sized fixed-headstock lathe, so are less costly to run, particularly with energy prices rising so fast.

The other main plus-point is the ability to reduce cycle times, as the ganged turning tools and powered tools are very close to the component, so have a shorter distance to travel.

For the same reason, accuracy is often better too.

As to his selection of Star for his first sliding-headstock lathe, Doughty pointed to the machine's heavy, rigid structure, which lends itself to better accuracy and longevity over many years of 24h operation.

He has also been impressed with Star GB's back-up, in particular its assistance with programming while DPE was learning the technology, and the supplier's willingness to help develop the in-cycle shaping operations.

* About DPE - founded in 1925 by Alan Doughty, Peter Doughty's grandfather, DPE is now part of the Nasmyth Group.

The company originally specialised in manufacturing diesel fuel injector parts for locomotive engines.

Aerospace connector contracts gradually took over and now account for all of the business.

Around 40% of output goes to UK customers, with most of the remainder delivered to the USA.

Concluded Doughty, ' During the mid 1990s, we were finding that repeated 'cost-down' requirements from aerospace customers were eroding margins to the point where jobs were becoming financially unviable.

It became impossible to manufacture aerospace components economically without minimising the number of separate machining operations, so in 1997 we started down the fixed-head, twin-opposed-spindle, mill-turning route.

Purchase of the Star sliding-head mill-turn centre, which has even more CNC axes, has been a logical extension of that policy and is getting us even closer to one-hit manufacture.

By taking advantage of a supplier's 'previously owned' CNC sliding head automatic lathe service, a subcontractor has been able to keep pace with a growing order book for precision turned parts.
CNC sliding head automatics meet demand By taking advantage of a supplier's 'previously owned' CNC sliding head automatic lathe service, a subcontractor has been able to keep pace with a growing order book for precision turned parts By taking advantage of NC Engineering's 'previously owned' citizen cnc sliding head auto operation in the UK, Heeler Engineering of Kislingbury, Northampton, has been able to keep pace with a fast growing order book for precision turned parts and maintain deliveries to its commercial vehicle sector customers. Said managing director Martin Heeler: 'In 2005 we produced 4 million shafts, adjusting nuts, pivot pins, piston rods, spacers, nuts, bolts and washers, an increase of over 500,000 components that we machined the previous year. Almost 40% of the parts are produced on Citizen CNC sliding head autos and by opting for used machines as against new, this has allowed us to continue to install spindle capacity exactly when we need it.' As he explained, it is not all about reducing financial burden, Heeler was able to buy three machines in a package from NC Engineering to meet a large contract and immediately respond with a highly competitive quotation to win the business due to single cycle machining and limited manning methods.

'Our risk is also lower if the contract should disappear, because NC Engineering has a realistic buy-back policy if they know the machines and its history, which gives us a confidence level to go after new work.' Heeler's six Citizens include an L32, an L25, three L20s and a B12 which gives the company a good spread of spindle capacity.

Heeler maintains production security, even against strict Kanban delivery schedules, is not compromised because of the inherent reliability of the Citizen machines.

'We have never been let down and the service support is just a phone call or email away.

Quite often we can be talked through a problem over the 'phone and a service call response is always very quick.' He maintained that with NC Engineering being the Citizen specialist for over 30 years, the pre-owned machines available have a known history, have been serviced regularly and therefore give confidence they will provide a high level of productivity.

He said: 'I chuckle when they say the machines are not secondhand but 'experienced', but that really sums up the performance when they are installed.' Heeler, which employs 20 people in the second-generation family-run business, is certainly busy supplying mostly local customers.

It produces 250 different parts for one customer, makes 2,500 of two types of shaft a week and 300,000 piston rods a year.

Machines are changed-over up to three times a week and many of the components produced are typical of the parts that have disappeared overseas over the last five years.

But Heeler is not too concerned with his investment and set up at Kislingbury he is confident he can remain competitive - but not complacent.

'I am not arrogant and any subcontractor is vulnerable to losing a contract.

By capitalising on our experience in the sector and combining operations into single cycles, we have been able to largely offset the difference in labour cost and shipment.

What we can provide is security of supply.

Our customers know the quality we can deliver especially from the citizen machines and we can action an immediate delivery response when needed.

The lifeline to the Far East or even Eastern Europe is proving to be an important factor in buyer's purchase decisions as they are concerned at being held to ransom, and this is now working in our favour.' Even when facing fast rising material costs, Heeler mainly machines mild steel and free-cutting ENIA, and the company has been able to absorb most of the on-cost by improved methods and techniques.

For instance, hexagonal or rectangular, bar is no longer purchased, cheaper oversize round bar is now milled in-cycle to create hexagons and squares and one particular shaft has a thread 190mm long with crossholes and flats.

This is now machined in 'one-hit' and dieboxed on a Citizen L20 rather than single point cutting and a set of chasers tend to last for 3,000 or so parts.

Many of the existing components are now produced in half the cycle times, and hence shorter lead times than previous methods, with cross-holes, threading, knurls, flats, recesses and full deburring all performed in-cycle.

To which Heeler insisted: 'The Citizen L20 is really our ideal machine with its combination of power, speed and flexibility.' The machines are left virtually unattended once set and a first-off approved.

To which foreman Melvyn Payne described his role: 'The machines are very consistent.

We normally rack-up with new bar around 5 pm.

As I live just down the road, I come back around 7 pm and again between 9.30 and 10.00pm to make sure everything is OK and then check the parts produced in the morning and pack them for despatch.

We do all programming offline and download ready for the next batch which minimises change-over time.' Heeler said: 'We are determined to be here in the next five years.

While the manufacturing scene is changing fast, it is not all in the hands of overseas producers, technology has a lot of advantages to offer if it is used properly - that is our strength.

Deep hole drilling and specialist sub-contract company Mollart has ordered an Integrex e-500 H multi-tasking machine, with 3m capacity, to machine complex parts after gundrilling.
Multi-tasking machine tool ordered at MACH 2006 deep hole drilling and specialist sub-contract company Mollart has ordered an Integrex e-500 H multi-tasking machine, with 3m capacity, to machine complex parts after gundrilling. Yamazaki Mazak's MACH exhibition success continues with the confirmation of a substantial order from deep hole drilling machine manufacturer and specialist sub-contract company Mollart . The order is for an Integrex e-500 H multi-tasking machine, with 3m capacity, which will be used in Mollart's extensive sub-contract facility at Chessington.

Its main role will be to machine extremely complex components in a single operation, after the preliminary gundrilling operations.

These components are part of a recently won contract from one of Mollart's customers in the oil and gas sector.

With some of the components measuring up to 2m in length repositioning for multiple operations is time-consuming and costly.

By using the Integrex e-500 H these costs are eliminated and, more importantly, Mollart will be able to guarantee the positional accuracy and concentricity of the multi cavity bores that are a feature of these particular components.

Guy Mollart, Mollart's managing director, said: 'We won the contract to manufacture these components on the strength of our ability to deliver on time and to the highest quality standards.

The Integrex e-500 H will enable us to maintain that business as we can reduce cycle times and lead times, thanks to the machine's ability to complete all operations in a single hit.' He added: 'However, the most important benefit is the fact that single hit machining enables the positional accuracy of the many features of these components to be maintained.

This would be extremely difficult to achieve if using conventional multi-operation techniques.'

Macro CNC sells a twin spindle, three-turret, 10-axis Miyano turning centre with 51mm bar capacity to Irish precision turned/milled components manufacturer, Mann Engineering.
The recent MACH exhibition at the Birmingham NEC proved the ideal opportunity for Mann Engineering of County Wexford, Ireland to become familiar with its new purchase - a Miyano ABX-51TH2 turning centre from Macro CNC. This twin spindle, three-turret, 10-axis Miyano turning centre with 51mm bar capacity has the manufacturing capability to produce complex/high-value parts efficiently in a single setup; the main reason behind the purchase. Mann Engineering specialises in the manufacture of precision turned/milled components for diverse industrial sectors.

Additionally the company designs and manufactures lathe bar feed systems and specialist tooling/fixturing systems for manufacturing applications.

A primary objective for the company will be market penetration into the highly competitive and demanding medical device sector.

Mann Engineering started purchasing CNC machine tools at MACH 2002 and has since acquired ten CNC machines, two of which are Miyano ABX-51TH2 machines.

Rolf Fuhrmann, managing director, commented: 'Since the introduction of the first Miyano, we have been able to produce parts in a single set-up with minimal labour involvement'.

'There are no second operations and this dramatically reduces cycle times when combined with increased product quality it enables the company to directly compete with off-shore competitors.' The first Miyano ABX-51TH2 was bought at MACH 2004 and was one of the first Miyano ABX machines sold in Europe.

The third turret on the machine has provided the company with sustainable productivity improvements in the order of 20%-30% and with such impressive results, it is no surprise the company has opted for a second machine.

The second Miyano ABX-51TH2 turn/mill centre was installed and commissioned the week after MACH 2006.

With this latest state-of-the-art machine the lower tooling turret, usually dedicated to the left spindle, can now be deployed on either spindle.

This additional manufacturing facility further enhances the manufacturing capability within the company and facilitates the company focus of providing cost-effective, high value added and high quality components to their expanding customer base.

With a solid order book and a customer base in excess of 50, the company sees investment in innovation and high specification machine tools, not only as the way forward but the only way to survive in such competitive times.

The commitment of Mann Engineering is summarised by John Stretton, general manager of Macro CNC: 'most subcontractors have a threshold and will work with 6- to 8-axis machines, but will go no further'.

'For Mann Engineering, like any other machine shop, it takes a massive leap of faith to invest in a 10-axis three turret fixed head machines.

For companies like Mann Engineering that are willing to take technology to the next level, the benefits can be remarkable.

This type of investment will enable Irish companies to level the playing field against cheaper foreign economies.' An example of this can be seen in the cycle time reductions at Mann Engineering.

One particular component previously taking 2 min 30s and four operations to complete is now being completed in 25s in a single operation.

Another job taking 20 minutes and five operations; it is now produced in 8 minutes complete on the Miyano ABX-51TH2.

Mann Engineering with the purchase of this additional Miyano ABX-51TH2 is proactively establishing itself.

The company fully realises the crucial role of CAD/CAM and co-ordinate measurement systems required to complement these CNC resources.

To address these issues the company has embarked on an InterTrade Ireland, Fusion graduate development programme in association with the University of Ulster, Belfast.

The primary objective of this cross-border programme will be to focus on business improvements, the integration of CAD/CAM systems and a CMM inspection facility.

'As a company we are committed to establishing continual productivity improvements.

Single hit machining and rapid changeovers together with the rigidity and additional power provided by the Miyano machines enables us to manufacture significantly more efficiently than any competitors in the Irish market.

We are at the forefront of technology and the acquisition of a second Miyano ABX-51TH2 at MACH 2006 will enable us to stay ahead of the competition,' concluded Fuhrmann.

Linear drives, 'high-end' controls and a novel tool box system in CNC universal lathes have stimulated demand, such that DMG (UK) is increasing machines in stock - including CNC millers.
To meet an increasing demand for its most popular machines on short lead times DMG (UK) has taken the unprecedented step of establishing a range of stock machines. These include both milling and turning machines and cover a wide range of performance requirements. In the CNC universal lathes category the options extend from the NEF 600 and CTX 10-series models through to the CTX 620 linear that provides up to 28% higher productivity thanks to the linear drive, high-end controls and a unique tool box system.

The single spindle Sprint monoBLOCK and twin spindle Twin turning machines are readily available as is the GMX400 linear for six-sided machining with up to 90mm bar capacity and 12,000 rev/min milling spindle.

The entry-level DMU 50, the DMU 60 and 80 monoBLOCK and DMU 50 eVolution linear models for five-sided/5-axis machining provide a wide choice of CNC universal milling machines.

And the choices continue with DMC-V vertical machining centres and models from the DMC U universal machining centre series with pallet changer for 5-axis machining.

All machines are available for immediate delivery and may also be supplied on an attractive rental or lease basis.

Their price includes full programming and operator training and delivery within the UK.