Most of my work is a very low lot size (1 to 10 parts).  How can I automate this?

These technology improvements include machine tools with PC-based controls and built-in networking capabilities, high-precision palletizing tooling, and state-of-the-art software that allows the user to change production needs with the click of a mouse. These improvements allow us to design cost-effective automation solutions that enable the smaller production operations to run 24/7. The other change in the market is that these same requirements are becoming more prevalent with larger manufacturers as their production requirements become more “Just-in-Time” to meet the demands of reduced inventory and shorter product development cycles.

No two parts are the same size.  How do you automate this type of work?

When an automated cell is designed to load a specific part, its workpiece gripper and fixturing are designed to meet a very specific need. This prevents the cell from being utilized for other work in the shop and can even render it obsolete if that particular job diminishes in production.

With the advent of high-precision tooling systems (that can be pneumatically or hydraulically controlled) we can change the automation system to load and unload a standardized pallet into the machine tool. This enables any type or size of work to be loaded onto this pallet, making the cell capable of loading work of all sizes and shapes.

The next challenge in this type of system is how to deal with the many NC programs that must be sent to the machine tools in order to produce a large amount of dissimilar parts. This can be accomplished with the addition of a Cell Control software. In this case the Cell Control software (like ATI's CellMaster product) manages all of the work to be done in the cell and only sends the information to the machine tool after the particular part has been loaded. This enables the operator to make schedule changes with the click of a mouse from the Cell Control PC on the shop floor without stopping or disturbing the machine tools in the cell. This flexibility has revolutionized the Job Shop and made automation possible for this type of manufacturing.

Do I need to purchase new machinery to automate, or can I use my existing equipment?

Many of today’s CNC machine tools have the capability to be used in this type of an automated system. If your current machines do not have the features necessary, then upgrades or other solutions may be available from your machine builder. If you are looking at new machinery and you think automation may be in your future, it is always a good idea to verify that the required automation features are available on that equipment before you purchase it. ATI, Inc. can provide you with a list of machine tool features that are required for this type of automation solution.