Glueckler measures success in global market with automated cell
by Jerry Cook Competing in the global automotive marketplace has never been easy and isn’t likely to get any easier in the future. However, a recently installed advanced automation cell is now giving Glueckler Metal Inc., Barrie, ON a significant edge in the fiercely competitive global auto market.
“To be in the global market as a North American Tier 1 or Tier 2
automotive supplier, we have to be thinking automation in almost every
basic human interaction. That is what has led to the installation of
the automation cell,” says Anthony Glueckler, president of Glueckler
Metal.
Continues Glueckler, “It was an evolution of understanding of the
nature of the industry and where the quality constraints exist within
the older, traditional machining methods. (Historically) an operator
interacts with a machine tool and a measuring device and then has to
extrapolate data from the measurement of the component at that point
and then re-introduce it to the machine tool. That process is fraught
with incapability because everyone deciphers (information)
differently.”
Glueckler Metal, which began operations in 1987, has 110 employees. The
firm has three facilities totalling 98,000 sq. ft. Glueckler Metal
specializes in precision machining for a variety of customers in the
global automotive market for the light passenger vehicle, heavy
transport, and off-road sectors. “We are a Tier 2 supplier primarily
serving Tier 1 OEMs throughout North America and Europe including
Magna, Dana, Arvin Meritor, TRW and others,” says Glueckler. The
company’s sales are split 65%-35% between export and domestic sales
respectively.
The firm is typically working with low carbon steel from 1/2 in.
diameter to 3 in. diameter. The firm can easily hold tolerances ranging
from plus or minus .001 in. Glueckler Metal, which is QS9000/ISO9001
certified, is a high volume manufacturer with part volumes ranging
from 5,000 up to 10,000,000. “Our sweet spot is between the 50,000 to
500,000 pieces range,” he says. The company provides an extensive array
of services including CNC turning, CNC milling, CNC machining,
grinding, sawing, and more.
According to Glueckler, prior to installing the new automation cell,
parts were inspected and measured manually. “Previously, we had a
number of smaller cells which involved exchanging the part between two
lathes and a mill. We would create a blank using our multi-spindle
machines and then transfer the blank through three different machines
and then measure it. The problem was the time lag involved. For
example, if the first turning wasn’t performing correctly, you still
had two more turnings of the component before you would find (the
mistake). The operator might find that the measurement was out of
specification and then have to go and make the adjustment on the
machine tool and then clear out all of the (out of specification)
parts. The whole process didn’t have strong capability.
“As well, we had approximately 75 to 80 people manually inspecting
components at the machines but then the product would go through a
second 100% verification with various advanced error gauges and
electronic gauges. In order to provide 100% verification in a manual
operation, the part had to be checked twice. We also had a special
machine that we used to 100% gauge the thread on the part as well as
other specifications and tolerances that were tricky to do by hand,” he
explains.
Continues Glueckler, “However, that economic model doesn’t work in
today’s global market. Twenty years ago you could probably get away
with all of the additional measurement systems and you wouldn’t be too
stressed or pushed to the extent of having to put an automation cell
together.”
Because of the lack of repeatability and consistency in the manual
inspection operation and in order to improve quality and productivity,
the company began exploring automation systems that could perform the
same functions. Glueckler Metal subsequently installed the automation
cell last year.
The automation cell comprises a Mitutoyo MACH-V 9106 coordinate
measuring machine, 10 Nakamura-Tome WT-150 CNC turning centers, an
underground scrap metal removal and coolant filtration and
pressurization system, five robots, and two transfer areas. In total,
the automation cell covers an area of 3,229 sq. ft. and represents a
capital investment of over $5 million. The Mitutoyo CMM was supplied by
Mitutoyo Canada Inc., Mississauga, ON (mitutoyo.ca); the Nakamura-Tome
turning centers were supplied by Elliott-Matsuura Canada Inc.,
Oakville, ON (elliottmachinery.com), and the linear robotic line was
designed and installed by NH Global Design, Chatham, ON
(nhglobaldesign.com).
At the heart of the cell is the Mitutoyo MACH-V 9106 CMM. In the
automated process, the part is delivered from one of the CNC turning
centers by means of the robotic line to the Mitutoyo CMM for
inspection. Once the part is checked, the information is then
transmitted by the CMM back to the turning center that made the part so
any corrections can be made. If the part is out of specification, it
goes to a reject area. If the part is within specification it is
delivered to a loading platform. Once the CMM sends an offset back to
the lathe, all the parts in process go into a queue and are held until
the part with the offset is received. In addition, as a cutting tool
starts wearing or other specifications start changing, the CMM
automatically adjusts the CNC machine tool based on the new
information. Every third part is inspected by the MACH-V 9106 CMM.
Approximately 200,000 components per month are machined in the
automated cell.
Mitutoyo’s MACH-V Series CMMs have been designed to meet the needs of
flexible production lines. The system adopts an open structure to
optimize structural design. This design structure allows high
throughput, with traverse speed up to 866mm/s and acceleration of 0.86G
while maintaining a maximum accuracy within E=2.5 + 3.5L/1000.
“The Mitutoyo CMM provides direct feedback loops to the Nakamura-Tome
turning centers. The system is bullet-proof because it is the exact
same measurement tool for every machine,” notes Glueckler.
The automation cell has provided Glueckler Metal with a variety of
benefits, says Glueckler. “We’ve downsized our total square footage
from 110,000 sq. ft. down to 98,000 sq. ft. and downsized our staff
from 180 to 110 people and it is due to the automation.”
The cell has also provided the firm with significant improvements in
scrap reduction, says David Ellison, process manager with Glueckler
Metal. “Compared to where we were using our old systems, we are four
times or five times better in terms of scrap reduction,” he notes.
Not only is the scrap rate significantly improved but the automated
cell has provided enhanced capability to hold even closer tolerances
and improved quality, says Glueckler. At the same time, Glueckler
Metal has seen productivity at least double as a result of using the
automated cell.
Another element of the automated cell that contributes to quality is
the underground scrap metal removal and coolant filtration and
pressurization system. “The system automatically takes away the scrap
metal that is produced by the machine tools which allows us to have
100% uptime on the cell compared to having to do clean-ups on a monthly
basis with the individual, standalone machines. The system also cleans
the coolant down to less than 30 micron particulate,” says Glueckler.
In fact, Glueckler is so impressed with the automated cell that the
company is currently putting together a program to install a second
automated cell in the near future. mitutoyo.ca
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