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and different threading operations. Te API product uses dif- ferent operations and different tooling. Legg recalls his immediate reaction. “When I saw the


Okuma coupling cell at IMTS 2008, I thought, ‘Tat’s the way to go.’ Tey were about 60% of the way there in terms of de- veloping the process. It would just take a little more research


is integrated using MacMan-Net, a networked machine management program for CNC monitoring. “I always liked Okumas because of the mechanical positioning,” said Hoijer. “Now, I’m a fan of the programming capabilities. It’s very simple to program using a standard format. You can do it on the machines, or you can upload to a flash drive and plug it


The company’s consistent growth rate of more than 100% annually is the result of competitive advantage gained through the low overhead enabled by automation.


to determine how to integrate API tooling with the automated cell. One thing was clear to me. I knew Okuma could manu- facture the API coupling.”


A New Automated Process Okuma and distributor Hartwig worked with the LB Pipe


team to customize the process for machining the couplings to make the API threads. Te front end of the process was streamlined by adapting a rotating head cutoff machine so that coupling stock could be cut into exact lengths, each hav- ing a good face on a square part with a ready OD clamper. Tis is necessary for repeatability of the coupling cell and its robotics, and also eliminates some of the manual labor as- sociated with the traditional bandsaw approach. “What used to be our regular saw time is now the same as our complete run time,” said Legg. With the parts prepped for the coupling cell, integrated


support equipment orchestrates the workflow. Te blanks go to a robot, which loads two Okuma 2SP-V60 twin spindle four-axis vertical turning lathes, unloads them and then places them on an outbound conveyor. With this new process in place, the results were then


measured. Te general rule of thumb in the industry is three people per spindle. With the automation cell in place, it now requires only 1.5 people per spindle. Today they’ve added six more Okuma machines. In this one work cell, with a total of 18 spindles, each now requiring only 1.5 workers per spindle, 27 people can do what would have required 54 people using the old technology. Teir reject rate of less than 0.5% adds to the productivity equation. Steve Hoijer, the plant manager, has many years’ experience


with coupling manufacturing. He sees additional advan- tages with the automation. “You want to keep guys out of the machines,” he said. “When you’re running tons of material per week, that’s a lot for human bodies to take. Plus, machines don’t complain or call in sick. Te amount of material we can now move is pretty amazing.” Hoijer also handles programming for the machines.


Each has its own Okuma THINC CNC control to dial in the instructions for the operation. Te entire group of machines


into the USB. Tis makes the process effortless, as far as I’m concerned. Te control has tons of memory so you can store all your jobs in there.” LB Pipe’s Quality Manger Courtney Ashmun sees anoth-


er advantage to automation. All of the instrumentation used to gage parts is electronic. Since it’s an auto-comp system, the operator doesn’t need to change any of the settings on the machine. When parts are mic’d and gaged to make sure they stay within API standards, the offsets for the machines are auto-comped back to the spindle that the operator selects. “Human error is eliminated, or very unlikely,” says Courtney. “Tis means a lot more time and manpower can be spent on inspection.”


The Path of Productivity While most of LB Pipe’s employees have experience run-


ning CNC machines to make couplings, the equipment and automated process is all new, so training is important. Okuma and the other partners have been supplying this training. Te overall productivity increase to date stands at 10-15%.


Tese efficiencies will compound as more automation equip- ment is added, which is on the near horizon. Even with more equipment going in, there will be minimal additional work- force requirements. Te automated process has also increased consistency. With the old manual process, couplings-per-hour would drop off over time. Now, according to Legg, “With au- tomation, you get the same number of parts hour aſter hour,” he said. “It’s very consistent.” LB Pipe is now API and ISO 9001:2008 certified, which helps them acquire more business. Much of their new business is in supplying parts for fracking, which is becoming increasingly popular due to technology advances that make the process more powerful in getting the flow of production out of the ground. Te Okuma coupling cell created an enviable advantage for


LB Pipe. “With automation, we now have a unique competi- tive advantage that creates a platform for continued success,” said Legg.


This article was edited by Yearbook Editor James D. Sawyer from material provided by Okuma America Corp.


Energy Manufacturing 2013 77


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