Needing to increase its flexibility, remain competitive and widen its market opportunities a subcontractor purchased three sliding head turning centres that could be updated as business grew.
Many subcontractors and general machine shops throughout the UK are concentrating upon survival above all else. Then there are the machine shops like WML Engineering of Swansea that continuously invest in modern technology and strive to be a tier 1 supplier. WML was established in 1970 and since its conception it has been devoted to producing high precision turned components for every facet of the manufacturing industry.

WML has always been committed to sliding head machines for large batch and medium production.

However, with components becoming more complex, the company has needed to increase its flexibility not only to remain competitive but to widen its market opportunities.

To improve flexibility and market opportunities WML purchased a pair of Tornos Deco 20A sliding head turning centres with 25.4mm diameter bar capacity in 2002.

The dramatic improvements in flexibility and productivity saw the company acquire a Deco 26A single spindle sliding head machine with a 32mm diameter capacity in 2003.

All machines were specified with integrated barfeeders and swarf conveyors.

Since acquiring the machines, the confidence on the face of company director Jason Meir is evident.

Meir comments: 'We now have the ability to take on all types of work.

We have never had such sophisticated equipment to brag to the market.

Our next goal is to achieve Tier 1 supplier status in the automotive sector.' One of the main reasons that persuaded WML to purchase a series of Tornos machines was the modular set-up.

Meir commented: 'When we were looking for a machine it was apparent that many competitor machines could not be upgraded or accept add-ons, and what you see is what you get.

With the Tornos machines it is simple to retrofit many additional attachments and options, this is ideal for us as we can add a thread whirling attachment to manufacture a series of screws if we consider entering the medical sector.' The flexibility of the company can be recognised by its work base.

Up to 70% is within the automotive sector with the other 30% split between the white goods and leisure industries, which include components for golf buggies and remote controlled cars.

At present the company is manufacturing handbrake and accelerator cable components along with connector adjustments and steering racks for a major Japanese automotive manufacturer based in the UK.

Since the introduction of the Tornos machines WML has been invited on a weekly basis to provide feedback and input into the design process of products.

The capabilities of the machines enable WML to offer the value added service of designing improvements into the product to 'cost-down the process'.

This is especially the case with older products that do not take into account the sophistication of the modern machine and the possibility of components being produced in one operation instead of 3 or 4.

Working in the cutthroat automotive sector has provided WML with a number of challenges, one of which is working on a JIT basis.

A number of customers have even requested a 24-hour turnaround.

To enable the quick turnaround WML sets 3 machines for automotive work at a minimum blanket load.

If the machine has the capacity for 6 different jobs per week, WML will load 3 jobs and leave the additional capacity for emergency work.

Despite working in this manner the company is still working 24 hours a day, 6 days a week at 85% capacity.

WML currently runs 9 jobs at any one time on a JIT basis; to provide greater flexibility WML may purchase two more Tornos machines in 2004.

The reason WML will take on more Tornos machines is firstly for its flexibility.

The Tornos machine can produce steering racks in one operation, which includes deep hole drilling to 300mm via an attachment with coolant receptors plus surface machining to within a 2 micron tolerance to a ground finish.

Probably the most significant and beneficial component of the machines to WML is the software.

Meir continues: 'Machine tools, like PC's can be out of date within 6 months.

However, with the TB-Deco programs, the software is run from the offline PC and every 6 to 8 months Tornos will send the most recent version of software, which will ensure modern day machine speeds on aging machines.' This not only reduces machine depreciation but has persuaded WML to buy a fourth Tornos machine.

The company bought a refurbished Deco 2000 last summer in the knowledge that the software updates will ensure productivity of a modern machine.

The TB-Deco software enables WML to program a complex job within 20 minutes, which is then ready to run on the machine.

The program is completed via computer simulation, which will run in real-time mode, breaking down every facet of the process to monitor and optimise production cycles.

This also enables WML to provide customers with exceptionally accurate quotes for work.

WML has optimised programs via the software for heavy cuts and loads on stainless steels and titanium by using balanced turning, which uses two tools simultaneously to divide the load between the cutters enabling turning from 25mm to 5mm in one pass.

Using such methods through the software reduces cycle times by up to 40% on the majority of work.

One example at WML is a steering rack shaft that requires cross drilling, milling and heavy turning.

By overlapping the processes WML slashed 30 seconds off the production cycle.

Considering the company produces batches of 5,000 each month, the savings are considerable.

With the program and software stored on the PC, the program is downloaded and processed on the machine in binary code enabling all programming to be completed away from the shop floor.

Removing the programming skill from the shop floor enables the programmers to re-program offline in a suitable environment.

The TB-Deco software integrates all facets of the machine including the barfeeder, swarf conveyor and the tool changes.

The off-line tool pre-set option informs the operator when a change is needed.

This enables the operator to prepare a replacement tool for when the machine stops instead of changing the inserts and re-starting the machine, an option that can save minutes each shift.

With regards to the software integrating machine peripherals like the barfeeder and swarf conveyor, the advantage is considerable to WML.

The TB-Deco informs the operator how many components are left to machine and the specific time the feeder runs out.

This enables the company to prepare for each production run and improves material and stock scheduling.

Even the swarf conveyor plays a significant role for WML; a manipulator arm moves the component to a part bin while the swarf is moved to an isolated bin away from the work.

The coolant sump with a 500 litre capacity is also integrated making the machine and all peripherals one complete and encased unit.

As the company is currently in the process of ISO: 14001 accreditation, enclosing the swarf conveyor and coolant sump into one enclosed unit to ensure tight control over coolant and waste is a major consideration.

Meir concludes: 'The Tornos machines are shaped correctly for our market as they are ideal for the automotive sector.