The machine operator at TRD says he sets up the Enshu HMC for his shift, as well as a virtually unattended second shift. The HMC runs in tandem with a Fastems 10-station (5 x 2) pallet changer.
Fifty-six block sizes are run at TRD, producing over 450 different parts, in one-off to 500 piece quantities.
AME tombstones on the pallets of the Fastems loader, feeding the Enshu machining center.
Various arrangements of workpieces are possible with the custom Triag tombstone type workholding devices provided by AME to TRD.
In its production of various cylinder and related products for hundreds of customers, TRD Manufacturing, Inc. of Machesney Park, IL (near Rockford), was challenged by an ever-increasing variety of sizes, styles and materials in their workpiece blocks.
"TRD is a fast-paced manufacturer but very dedicated to high quality and fast turnaround on deliveries," said Kerry Reinhardt, VP of Operations. "We have an established reputation as a solution provider to the fluid power industry." The company sells through distribution with its end users found in the general manufacturing, automation integration, mining, forestry, medical, food and various mill industries. TRD products are regularly specified as OEM components, plus the company serves the MRO marketplace.
Meeting the demand for products in an ever-expanding line was complicated by just-in-time delivery schedules that were often encountered. "TRD was seeking a partner who could develop fixturing to fit our manufacturing business model of quick set-up and the flexibility to run small or large batches of product from a multitude of block sizes," said Tom Jensen, Manufacturing Manager.
TRD turned to a local supplier of various machine tool components, Advanced Machine & Engineering (AME) in Rockford, IL. The head of the AME workholding group, Alvin Goellner, said, "After a few discussions and visits to each other's plants, we knew TRD would benefit most from our Triag line of modular workholding devices."
"We knew AME had a reputation for building top quality fixturing," said Jensen. "Their in-house manufacturing capabilities were very impressive. We knew they could handle a project of this size based on the other customers they serve, and the fact that they are just across town from us made it easier to work through the preliminary discussions, quoting and final product delivery."
The horizontal machining center (HMC) used for this particular application at TRD is an Enshu GE480H, with 30" x 30" x 30" travel and a 180-position toolchanger, expandable to 240-position. Workpieces are mounted and handled on a Fastems 10-station pallet changer. Currently, the block sizes run at TRD are 56 in number and run in sizes from 1" x 2" x 2" to 3" x 9-1/2" x 14". Weights range up to 114 lbs. Final part varieties produced on the machine number over 450, made from 1018 steel and 303 stainless. Lot sizes vary from one-offs to 500, but generally run between 25-50, on average. This machining center set-up runs two shifts per day, with the expectation of running 24/7 during peak demand periods.
The challenge for Alvin Goellner and his team at AME was to design a series of fixtures that was flexible enough to hold 56 different block sizes, offer quick changeover and offer the ability to run different parts on each side or run multiple pallet loads of the same part in high production, when needed. "It was a real one-size-really-can-fit-all situation," said Goellner. "We knew the HMC with pallet changer was very costly to run, so keeping downtime to a minimum was essential."
The solution came in the form of 10 Triag custom modular tombstone-style fixtures from AME, who partners with Triag, a major European workholding component supplier, as their exclusive North American distributor.
"The fixturing in our existing machining cell was fixed, based on block size," said Jensen. "AME fixtures use a vise system that quickly adjusts to any size with repeatability, a key factor in the equation as it allows all our work shifts to be pre-taught the process. We normally have the fixtures set for specific part sizes, but this AME solution now allows us to run any size part on any pallet very quickly for high-volume jobs. There was a very short start-up time in the TRD shop, as the flexibility of the tombstone design and the fixturing mechanisms were relatively easy to learn for the operators.
"We met with Alvin Goellner and brainstormed the improvements needed on our current fixturing system. AME laid out a concept and provided drawings for each fixture, which we then reviewed and approved, based on our current production schedules and anticipated workloads going forward. All the fixtures ordered arrived on time or ahead of schedule, a very refreshing experience. Goellner was the lead man for AME on the project, bringing his 20+ years of fixture design and build experience to the task. Because all aspects of this project's customized manufacturing, assembly and test of the Triag tombstone fixures were done in-house at AME, there was little delay in the processing of the project and all design changes were quickly accommodated."
"The overall experience was excellent and the results have been outstanding for TRD," said Reinhardt. "The project went well and all our expectations were met. The improvement percentage in production on the Enshu HMC is estimated to be over 40% after several months in operation."
TRD combines 27 years of precision machining and engineering with a selection of options and modifications to deliver high quality customizable NFPA (National Fluid Power Association) cylinders. TRD is a division of Bimba, a provider of actuation devices.
Advanced Machine & Engineering Co. is a manufacturer serving the machine tool industry with precision components and accessories, including spindle interface components, workholding devices, and, through its sister company, Hennig, machine enclosures, chip removal and filtration systems.
For more information contact:
Kerry Reinhart
TRD Manufacturing, Inc.
A Bimba Company
10914 North Second Street
Machesney Park, IL 61115
815-654-7775
reinhartk@trdmfg.com
www.trdmfg.com
Alvin Goellner
Advanced Machine & Engineering Co.
2500 Latham Street
Rockford, IL 61103
815-962-6076
info@ame.com
www.ame.com