faster setups/changeovers and less operator intervention. And multitasking capability gained from our Mazaks helps us accomplish all these objectives. Plus, the machines are extremely accurate, provide more part processing flexibility, and fit well with our production flow cell concept,” Mazurek said. Once Conmed models a new
product in CAD and proves out feasibility, that product segues to the design phase and into a developmental cell. These cells determine manufacturability and ensure a smooth transition of a new product and its components into full production. Conmed runs parts in developmental cells until the product matures, after which the product’s components will move to production flow cells to step up throughput and meet the growing market demand. “Developmental machining cells get us to market with new products as quickly as possible, while flow cells provide speed and efficiency once those products are in full production,” said Rob Kalo, factory manager and chief engineer. “During product develop- ment, we generate a lot of iterations to achieve optimum designs, and using our dedicated development cell we provide flexibility and speed. Speed is critical, and the Mazak Integrex i-100S develop- mental cell provides that by allowing us to process very complex components on one machine and in single setups.” “Our goal is to keep job changeovers in our cells to a minimum,” said Kalo. “Non-cut times are just as, if not more, critical to us than part machining times. We constantly evaluate exactly how long machines sit idle because the longer they do the more our efficiency suffers.” Conmed runs its most recent Mazak
production flow cell in two-shift opera- tions. Parts enter the cell as raw material, go from the Mazak Integrex 200SY multi-
March 2016 |
AdvancedManufacturing.org 51
tasking machine to the three-axis VCN 410A, then to EDM and honing machines, if needed, and finally to secondary operations such as tumbling surface finishing, washing, and anodizing. All gaging, measuring, and inspection are also done within the cell.
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