Super-charged productivity at Petron

As the COVID-19 pandemic pushes healthcare services to their limits, the Tornos SwissNano is helping a US-based subcontract machine shop, Petron Automation, to supercharge its production of a complex, tight-tolerance component for much-needed ventilators.

Many manufacturers of small, challenging medical device components turn to Petron Automation for the quality required in the risk-averse medical sector. By the same token, Petron Automation has turned to Tornos for precise manufacturing solutions, including four SwissNano 4, two EvoDeco 32, two EvoDeco 16, two MultiSwiss 6×32 and three Deco 13 models.
“In early March, we were at the end of our first-quarter 2020 order for a specific ventilator part for an important customer, who told us we were going to have a huge uptake in these components.”
At this point, Petron Automation had been producing 5000 ventilator armatures per week for that customer, which asked the business to ramp up to 20,000. The SwissNano sliding-headstock lathe helped the business double its production capacity for the armature within a week. Machined from bars of 430FR stainless steel, the part carries critical tolerances ±0.0088 mm.
Paul Thornberg, VP of business development at Petron, says: “It’s got some tight tolerances and we must maintain very sharp edges with maximum edge breaks of 0.0127 mm and surface finish under Ra10 μm. We are producing 2000 pieces per machine, 10 hours per day, holding those tolerances.
“The reliability of our SwissNano machines allows us to run these parts lights out with very little tolerance deviation,” he continues. “One of our SwissNanos ran for 23.9 hours on 13-14 May, and the other ran for 23.4 hours on the same day. That’s a testament to the capability of these machines.”
For further information www.tornos.com

Fit for the future

Somerset-based Watson Gym Equipment, a manufacturer of specialist strength training equipment used in high-end PT gyms, has recently invested in two new Doosan machine tools and a Doosan collaborative robot (cobot) from Mills CNC.

Watson Gym Equipment, created by owner and managing director Simon Watson in 1999, acquired its first Doosan machine, a large-capacity Puma 4100MB lathe, in March 2020.
This 15“ chuck, box-guideway Puma 4100MB is a rigidly designed and built machine suitable for a range of heavy-duty machining operations, including interrupted cutting. The Fanuc 0iT-controlled machine is equipped with a high-torque 30 kW/2000 rpm spindle, a servo-driven tool changer (12-position) and driven-tooling capability (7.5 kW/4000 rpm).
Since being installed, the lathe has been used to machine the company’s Pro Olympic weight plates, which are made from solid marine grade stainless steel. Weight plates are the flat discs located at either end of a weight bar to create a barbell or dumbbell used for weight training.
The acquisition of the Puma 4100MB lathe had an element of serendipity about it. In late 2019, Watson Gym Equipment had approached its existing CNC machine-tool supplier to discuss the best way to ramp up the production of its weight plates in order to meet increased demand.
Initial discussions centred on the acquisition of a new large-capacity vertical turning lathe to machine the components but, with an anticipated delivery time approximately six months after order placement, the company decided to consider alternatives and approached Mills CNC for help.
Says Watson: “We were aware of Mills CNC and knew that the company had a good reputation in the market for the technology it sold and aftersales services. We approached them to see if they could help with our specific machining capacity issue and, after an in-depth discussion, they recommended the Puma 4100MB. This large-capacity horizontal lathe was available from stock, and could be delivered and installed almost immediately.

“Mills took the time to understand our company and bought into our business model and what we were trying to achieve,” he continues. “They pointed out potential tooling interference issues that could occur by going down the vertical turning lathe route and, instead, demonstrated the productivity and flexibility benefits that we could expect to gain from investing in the Puma lathe. All of which, incidentally, have been correct.”
Watson weight plates can be supplied to customers in a range of standard sets (such as 150, 250, 350 and 500 kg) with individual plates weighing between 5 and 25 kg. All weight plates are machined to high accuracy and exacting surface finishes. Features include powder-coated end plates that can be customised (if required) with a customer’s logo or brand, and are supplied with a lifetime warranty.
“It’s relatively easy and cheap to manufacture weight plates from mild steel and add zinc- or nickel-plating to provide a professional looking finish,” says Watson. “However, after a short time, and through constant use, they will lose their lustre and the coating will peel, chip or discolour. Our business model is focused on manufacturing high-quality, high-performance and competitively priced premium products and equipment that look the part and which stand the test of time. That’s why we use stainless steel for our weight plates.”
Stainless steel is also used for the company’s range of best-selling dumbbell handles.
In early 2020, Watson Gym Equipment, with demand for its dumbbells at an all-time high, made the decision to increase its in-house production capacity and approached Mills CNC for guidance. Of particular concern was how to increase production of the company’s heavy-duty dumbbell handles, which are available in different lengths with a 30 mm grip.
“Dumbbell handles are not complex components,” states Watson. “They are machined from bar and cycle times are short. To meet increased customer demand we needed additional turning capacity, and we needed it fast. Having already established a good working relationship with Mills through the acquisition of the Puma 4100MB, we approached them again with our requirement and they recommended the purchase of a Doosan Lynx 2100LSYB lathe with a Hydrafeed bar feeder.”

The 8“ chuck/ 65 mm bar capacity Lynx 2100LSYB is a compact, multi-axis turning centre equipped with a high-torque main spindle (11 kW/4500 rpm), a sub-spindle (5.5 kW/6000 rpm), a Y axis (±52.5 mm) and driven tools (3.7 kW/6000 rpm).
Doosan’s Lynx 2100LSYB is suitable for small part production and is said to be fast, accurate and reliable. The machine and bar feeder were installed at Watson Gym Equipment’s facility in early May 2020 and its production capabilities have recently been increased further with the addition and integration of a Doosan M1013 cobot, which was delivered and installed later in the month.
The cobot, with its 10 kg payload and 1.3 m reach radius, is positioned in front of the Lynx lathe and programmed to unload the finished parts (dumbbell handles) once machining operations have been completed.
Says Watson: “The job and machining process were ideal for automation. We can set up the job and leave the machine running unattended overnight. As a consequence we have improved our productivity significantly and, as we’ve effectively removed the labour component from the process, have reduced the cost per part as well.”
Plans are well underway to increase the company’s floor space by an extra 22,000 sq ft with the building of a new machine shop adjacent to its existing facility in Frome. The new facility is expected to be completed by the end of 2020 and will house all the company’s CNC machining operations, including a new ‘Synergi 25’ automated manufacturing cell from Mills CNC.
The cell, which comprises a Puma 2600SY lathe (with Y-axis and sub-spindle capabilities), a 25 kg high-capacity industrial robot, an automated two-way drawer system (for stacking, storing and loading workpieces and finished components), a 17” touchscreen HMI, locating plates, pneumatic grippers and Sick safety systems, has been specified and ordered to help the company meet growing demand for its dumbbells.
“Automation is the key to higher productivity, operational efficiency and improved competitiveness,” says Watson. “The Synergi 25 cell will help us increase throughput and reduce bottlenecks, and exploit lights-out, unattended operations still further. We will be working with Mills CNC’s automation specialists in the next few weeks and months to create and prove out a bespoke manufacturing process at their Automation and Turnkey Centre in Leamington prior to it being delivered to our new facility.
“In the past six months we have developed a strong and positive working relationship with Mills CNC based on integrity and trust,” he concludes. “The technologies they are able to supply and the added-value consultancy they provide are helping us optimise our performance…making us fitter for the future.”
For further information www.millscnc.co.uk

SC21 recognition for AS.G companies at virtual FIA

Two precision engineering specialists were recognised for their commitment to quality and delivery performance last month as the Farnborough International Airshow went ‘virtual’.

SONY DSC

Arrowsmith Engineering and TGM, both part of the £43m Aero Services Global Group (AS.G), were given the SC21 Silver and SC21 Bronze awards respectively for their ongoing ability to manufacture complex components for customers supplying some of the world’s largest airplane manufacturers and primes. The awards are a critical performance indicator for the sector and have helped the two manufacturers secure over £3.5m of new contracts during the past 12 months.
AS.G has made a commitment that all of its companies will work towards some form of SC21 involvement. This decision will immediately see the recently acquired AMF Precision Engineering start the journey, and German-based Ludolph target the SC21 Operational Excellence Award.
For further information
www.arrowsmitheng.co.uk www.tgmeng.co.uk

Lotus to build technology centre

Lotus is set to create a dedicated and specialist advanced technology centre that will also be home to a new headquarters for the company’s engineering consultancy.

Located on the University of Warwick’s Wellesbourne Campus, the new facility is established in partnership with WMG, a specialist in collaboration between academic research, teaching, training and industry. The substantial facility will consist of offices, workshops and laboratory space with ample opportunity for expansion. Initially, 130 engineers will move in, complementing the 500-strong engineering team at the home of Lotus Cars in Hethel, Norfolk.
“This is a big step forward for Lotus and our engineering consultancy,” states Matt Windle, executive director – engineering, Lotus Cars. “The new space, facilities and job opportunities at Wellesbourne will be in great demand as we rapidly build our portfolio of external projects.”
For further information www.lotuscars.com

Capability enhanced at Iron Mason

Iron Mason was founded six years ago by Chris Mason, who had worked in the film industry as a model maker and animatronics specialist.

The Derby-based company now provides engineering, fabrication and finishing services to a diverse customer base, including his old sector, film making.
Mason had recognised a lack of metal skills within the film industry so took the decision to ‘go freelance’. Diversification from the movies brought in work from classic car enthusiasts, as well as aircraft build and restoration projects.
“Basically, I will take on anything that comes through the door, I just have to be honest with myself and ensure it is within my capabilities,” he says. It was this notion that highlighted the need for CNC machining capability.
“Initially I was looking at a CNC vertical machining centre, but a customer beat me to it and made a purchase of their own, so I moved my focus to turning. My view was that, as a turning centre was a bigger investment, the competition
for available capacity in the local area would be less. I did my research and asked around, and settled on the CT65 Compact Turn from XYZ Machine Tools.”
Two of the key factors in the purchase decision were the build quality and control system.
“It was obvious that the CT65 was much more robust than other machines on the market thanks to its cast-iron base and box slide-way construction. I’m finding that it holds tolerances very well and repeatability is superb. The Siemens 828D ShopTurn Control is also very intuitive.”
Such is the intuitive nature of the control that Mason can adapt programs ‘on the fly’ and, in one case, reduced cycle time from
16 minutes to just six.
For further information www.xyzmachinetools.com