what’s most critical is that the cells basically eliminate human intervention within the process, greatly diminishing errors and deviation from one part to the next.
GN gave the Pioneer cell its name mainly because it is a completely new approach to manufacturing oil & gas industry equipment. The cell was also the company’s first venture into a major automation project.
The four Mazaks in the Pioneer cell double GN’s produc- tion capability by providing the output of eight of the shop’s other non-automated machines running 24/7. This cell also reduces labor requirements by 75%. The Pioneer operates three shifts, five days a week and typically for eight hours or more at a time without human intervention. All the machining, gauging/quality control and deburring happen within the Pioneer cell. Because the machines are multitasking, they allow the completion of parts in one setup and two operations. Plus, if needed, the shop can quickly and easily switch over to run a different family of parts.
Facing the Challenge Adam Jarantowski, GN’s head of manufacturing and the Pioneer line project lead, said it was a challenge to automate the cell’s particular part-processing operations because the parts and the machining they require are so complex. “To automate the processes and machine parts in as few operations as possible definitely required multitasking machines,” said Jarantowski. “Without the Mazaks producing the parts would require a lot more than just four machines as well as several additional operations.” Pioneer uses two FANUC robots. One, with a 600-kg ca-
pacity, rides on a rail to load and unload the machines, while the other, a smaller one, works at the part-gaging station. An in-line CMM measures parts and feeds the resulting data into the machine tools for on-the-fly offset adjustments, and completed parts from the cell are 100% inspected. Pioneer processes 4140 heat-treated steel parts requiring two operations and two machines, so two parts are com- pleted simultaneously. The cell runs a specific family of parts. Each of the machines can run any of the variations. Because GN opted for 160-tool magazines on its Integrex e-500s, the shop can load each machine with at least three sets of the same tooling, as well as accommodate boring bars up to 24" (610-mm) long for part diameters as big as 35.5" (902 mm). Redundant tooling allows the cell to run con-
tinuously and lights out. Operators are also able to replace worn tools without interrupting cell operations. GN uses a presetter and RFID chips/tags for all of the Pioneer cell’s tooling. Once a tool is set, its particular infor- mation is stored in the tag that the machines read and use to automatically make the necessary offset adjustments.
The Key to Success Alex David, manufacturing associate at GN, heads the
Frontier cell. He said the key to its success is the ability to complete parts in single setups on the Mazaks. The cell runs 24/7 and, for the most part, unmanned with one operator that keeps it supplied with raw material. Like the Pioneer cell, GN’s fully automated Frontier line
also relies on Mazak multitasking machine technology. The Frontier name represents the line’s use of special first-of-its- kind multiple-part-loading robot automation. Each Integrex i-200ST has its own robot that loads and unloads parts and moves them to a CMM for in-process gaging. The CMM provides the Mazaks with in-process offset information and checks parts once they are completed. If parts are out of tolerance, they move to Quality Control for evaluation to determine the cause. Plant Manager Juan Roubaud credits Pleša with further
strengthening GN’s drive in continuous improvement, especially in regards to advanced manufacturing technology. Roubaud said that the parts have, over the years, become much more complex. Processing them on stand-alone turning centers and milling machines has become inefficient and makes for long turnaround times, which, in the spirit of continuous improvement, is why GN first turned to multitasking technology. And now, said Roubaud, continuous improvement is the catalyst for the push for increased automation.
The Next Generation of Manufacturing Both Pleša and Roubaud agree that automation is the next generation of manufacturing. And for GN, Mazak is and will continue to be a strategic supplier. “Our relationship with Mazak goes back over 20 years,” said Pleša, “and they are an integral factor in the success of GN, not only as a partner in machine tool technology but also in automation. And many machine tool suppliers these days tend to fall short in that capacity.”
53 — Energy Manufacturing 2016
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