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Glueckler measures success in global market with automated welding cell |
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by Jerry Cook
 Barrie, ON-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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