The Challenge

In 2004 C&S Machine Products Vice President, Dominick Saratore, was faced with a difficult problem; How to increase the production of a high-precision part to meet the growing demands of his customer. The bottleneck of their production was a time-consuming and operator-intensive Wire EDM process required to meet the accuracy of the part.

One solution would be to add additional Wire EDM machines to the shop, but this would also increase the number of operator hours required to keep the machines running, not to mention the additional capital equipment investment needed to purchase the machine tools.  C&S Machine Products was already paying a lot for overtime to man their existing machines and floor space was also an issue in their EDM department.

The Solution

Mr. Saratore attended the IMTS Show in Chicago in September 2004 where he was introduced to a new concept of Wire EDM automation.  One that enabled him to use a 6-axis robot to machine parts in a one-off lot size.  After some deliberation, he decided to purchase an automated Wire EDM cell to meet his needs.

The cell was to consist of two Wire EDM machines (utilizing one of his existing machines, and one new machine of the same make and model), two magazines that could accommodate up to 256 workpieces, and a FANUC M-16iB 6-Axis Robot from FANUC Robotics America.  The cell would also be controlled by ATI's CellMaster Cell Control Software.

The Results

The cell was installed during the first quarter of 2005, and within 30 days after the installation and operator training had been completed, C&S Machine Products saw a doubling of the production output of their EDM department.  Not only did the automation increase the production rate of the parts in the cell, but it also freed up the operators and allowed them to focus their attention on other jobs in the shop, and increasing the production rate on other equipment in the department.

Additional Challenges

During the review of the project, it was determined that the parts (made from a high-grade tool steel) could not be put back on the rack after machining still wet from the Wire EDM process or they would rust.  The parts also needed to be manually cleaned and oiled before shipment to the customer.  This was another time-consuming and labor-intensive job that added cost to the part.

Part drying, cleaning and oiling stations were added to the cell. These stations used a compressed air knife to remove the excess water and then cleaned and oiled the parts automatically, immediately after machining. This additional station allowed C&S Machine Products to produce parts 24/7 in the cell.

The first cell was so successful that C&S Machine Products purchased a second cell in 2006 for another Wire EDM application and they are currently working with ATI, Inc. to determine where they can benefit from automation in other areas of their operation.

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