Agie Charmilles launches automation initiative

Agie Charmilles has launched a new initiative, aimed at precision manufacturers in the UK and Ireland, promoting the business benefits that can be achieved via automation.

The initiative, which focuses on five-axis machining and automation, demonstrates the improved profitability, increased productivity and reduced operational costs that can be achieved by embracing automation.

According to GF Agie Charmilles, there are a number of different reasons why manufacturers could and should consider automation solutions.

These include: cost down pressures; new business won or new business quoted for; need to improve profitability; need to improve cash flow; need to reduce operational costs and overheads; need to improve production flexibility; and need to reduce lead times.

But while these catalysts are increasingly commonplace, the company said many manufacturers have appeared slow on the uptake.

Steve Burrows, milling product manager at Agie Charmilles, identified that a major problem among UK manufacturers' that has affected their acceptance and take-up of automation, are the misconceptions and half-truths that surround the whole automation issue.

Burrows said: 'The take-up of automation in the UK and Ireland lags behind that evidenced in the rest of Europe and the US.

'Popular misconceptions that have affected automation investment include a belief that automation is only viable for large (OEM-type) organisations, and not for smaller SMEs; that automation only works in high-volume production environments; that automation isn't suitable for high-precision, complex part production; and that automation is an expensive course of action, and that a satisfactory ROI takes years to achieve.' Burrows said that 'nothing is further from the truth' and that 'there is compelling and substantial evidence, certainly among GF Agie Charmilles' five-axis customers, where automation is delivering the goods'.

One of the key elements of the automation initiative is to clarify the different types (or levels) of automation that are available to customers.

In essence, there are three types of automation that can be integrated with five-axis machines, and these differ in terms of their purpose, functionality, sophistication and cost.

The three levels of automation are self-contained automation via large capacity ATCs and integrated workpiece pallet changers - all available and equipped as standard on GF Agie Charmilles' five-axis machines; externally-integrated rotary and linear workpiece handling/changing systems and robots (for example, System 3R, Erowa, Fanuc systems), that can be integrated with/to a five-axis machine; and sophisticated flexible manufacturing cells and systems (for example, Fastems systems), that can be integrated to different machine tools and different manufacturing processes.

These different levels of automation are not mutually exclusive and customers can progress from say level one to either level two or three, should their manufacturing requirements and priorities change in the future.

However, irrespective of the optimum 'level' of automation selected at any given time, there are a number of prerequisites, Burrows said, that exist 'before automation can be successfully introduced or even attempted'.

These prerequisites are essentially concerned with ensuring there is a stable and reliable manufacturing process in place and that can accommodate the introduction of automation.

Burrows added: 'Automation is primarily concerned with improving productivity, increasing profitability and reducing operational costs - often a combination of all three.

'These are achieved by increasing the working week to enable the manufacturing process to operate overnight and at the weekends.

'These benefits are virtually impossible to achieve if automation building blocks such as: datum setting; workpiece measurement and inspection; in-process tool setting; powerful, fast and adaptive control system technology and software; sophisticated high-capacity swarf management systems and large-capacity ATCs are not in place.' To ensure the integration and transition to automation, GF Agie Charmilles adopts a technically consultative approach with its customers.

This approach begins with GF Agie Charmilles' turnkey project management staff and applications engineers auditing and acquiring an in-depth understanding of a customer's current and future manufacturing priorities, needs and requirements, as well as an appreciation of the key business drivers that have led the customer to consider automation in the first place.