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One of the fi rst parts that Dynamic started working on when it began this reshoring program was the differential car- rier for the four-piece four-wheel-drive transmission, 4T40 and 4T65. The carrier is cast-iron and a major driving component for the transmission. “It takes about 40 different tools to make this part on the nine-axis Puma MX2600ST. If I didn’t have the nine-axis machine, I would probably have to quote this part on two or three separate machines. That’s the way the part was being made previ- ously—on a sort of transfer line setup of multiple machines,” Jensen said. “Right now, we’re averaging between 60 and 800 GM 4L60 pump covers per month. And this is done right now on the nine-axis Puma MX2600. There are probably 20 angular holes in this part and there are three bores that also are angular, and a lot of angled holes that al- low us to use the B axis to put all those holes in at one time and hold tolerance of ±0.0002" [0.005 mm],” said Jensen. To run a family of 4L60 valve bodies, Dynamic brought in two Doosan HP 5100 horizontal machining centers, one with an APC. “We are running these with two four-sided tombstone fi xtures. We set this up in a fashion that we can run lights-out, and thus far we haven’t had any problems. In fact, we’ve accom- plished this with one operator running both a Puma MX2600 machine and one Doosan HP 5100 horizontal machining center. It’s our goal to get operators run- ning multiple machines, as well as doing spot checks for quality. With the pallet changer we will have six open stations so we can keep our 24-hr lights-out operation up and running,” said Jensen. A Doosan multiple pallet carousel system with six different carousels loaded with tombstone fi xtures on them allows Dynamic to load up six differ- ent part families, depending on their changing needs. “We have 180-tool


automatic toolchangers on both of our Doosan HMCs,” Jensen said, “and we can set the MPS system so it can have multiple valve bodies or multiple cases, so we can fi xture multiple parts or part families and with all the tooling we can


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April 2015 | AdvancedManufacturing.org 53


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