Multi-function CNC lathe builder has developed an integrated loading and unloading system within the existing machine footprint and it integrates with user specified material handling systems.

The European Machine Tool exhibition EMO 2005 was the launch pad for Colchester Lathe's expansion of its 'Lights-out' productivity package introducing new levels of automation involving multi-axis machining technology. At the exhibition, the six-axis Tornado T8MSY driven tool lathe with a Y-axis cross feed to the turret and the fully integrated seven-axis T6MS turning cell with a programmable APL5000 automatic loading system were demonstrated to wide acclaim of the company's international distributors and customers at the show. Over the last 12 months Colchester Lathe has pushed ahead its design and development programme and simultaneously re-organised the production of Tornado lathes at Heckmondwike in West Yorkshire to enable assembly to build the new machines using a cell-based strategy.

This was a major change to the previous flow line principle for the more simple two-axis Tornado machines that took market leading shares for the value for money turning solutions they provided.

The whole machine shop has been re-organised with its two flexible manufacturing systems running around the clock alongside large mill/turn centres and slideway grinding equipment.

Sheetmetal assembly for guarding, previously produced at a Colchester Lathe facility in Halifax is now fully integrated onto the shopfloor at Heckmondwike working double shifts with support of Electrox CNC laser profiling, press brakes and a new automated powder coating and cleaning plant.

In addition, individual welding cells now fabricate the bases for the Tornado lathe with a special area dedicated to ensure the base fill of the lathe structure with an engineered polymer concrete is correctly administered.

This is an important part of the company's patented 'Duo-Stable' construction that improves machine stability by some 300%.

Now with the two-axis, three-axis with driven tools, six-axis with driven tools, sub-spindle and Y-axis and seven-axis machines with integrated loading in the portfolio, the whole concept of design and build has changed while the 'value-for-money' philosophy has been retained as a 'brand' marker to this very competitive sector.

The T6MS APL is a totally novel Colchester development that integrates a loading and unloading system within the confines of the existing machine footprint.

At a stroke, this new development provides users with a 'Lights-out' chucking lathe machine package capable of extended running in unmanned situations with the loading system having the flexibility to integrate with user specified material handling systems such as part stockers, carousel palletising or conveyor systems.

In addition, such has been the detail involved in designing the system that it can be switched-out and parked clear of the working area allowing the machine to operate in a normal manned fashion.

The automation is fully programmable via teach pendant and operates through the Fanuc 18i-TB control with Manual Guide i software on the machine as standard while being integrated with Colchester Lathe developed automation programs.

As a result, loading sequences are combined with first and second chucking operations having automatic part transfer between main and subspindle for parts up to 80mm diameter by 100mm long and weighing up to 5kg.

The machine concept involves a loading beam mounted above and onto the headstock and running parallel to the centre line or Z-axis to link component storage at the headstock side of the machine to the cutting zone.

Powered via ballscrew and servo drives, a novel rotating arm mechanism carrying two hydraulic chucks handshakes with the user specified material handling systems.

The Tornado T6MS has a 440mm swing over bed and 220mm maximum turned diameter by 450mm long with a 54mm bar capacity and either 170mm or 210mm chuck size.

The 15kW, 6,000 rev/min main spindle and 5.5kW, 6,000 rev/min subspindle are serviced by a 12 station all-driven tool turret with 3.7kW, 5,000 rev/min drive.

Rapid traverse rates are 30m/min in Z and 25m/min in X.

Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that uses an encapsulated polymer concrete base fill mounted with a compact cast iron bed to minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.

A large-capacity two-axis vertical boring and turning machine - with high table speed - has been acquired by an aircraft engine component supplier to further reduce cycle and lead times.

When Paul Pochciol talks about product quality, service and price as the keys to success, he is not dissimilar to many other heads of manufacturing companies. But when he explains that the continued success of the UK's Manthorpe Group is based as much on the organisation's investment in its employees at it is on high-technology machine tools and production equipment, then it is clear that here is a man with a passion for what he does and for the industries and customers he serves. As head of a group of engineering and building products companies that between them supply own-manufactured products, sub-contract machined parts and fabricated structures, Pochciol has for the past 30 years built a highly successful manufacturing group on a basic, but demonstrably potent, principle: always buy the best machines you can afford - and always employ enthusiastic, motivated people.

'The most expensive and fastest machines mean nothing on their own,' he says.

'But if they are operated by people who are truly committed, then the result can be world-beating.

It is not easy finding the right calibre of staff - you need patience and tenacity - and you have to motivate them by showing them that the work they do, the company they work for and the environment they work in is dynamic and world-class.' He says: 'For too many years too many people in the UK have regarded engineering as a low-prestige industry - quite the opposite to its regard in Germany and Japan.

But there is prestige in engineering - high-quality machine tools operated by educated, skilled people do produce high-quality workpieces - and the Manthorpe companies, and our customer base, are testament to that.' His sentiments are clearly visible at each of the three engineering operations headquartered on the 13-acre site in Ripley, Derbyshire, where the watchwords are 'from concept design through manufacture to installation and commissioning': * Purpose Engineering - a specialist in complex and bespoke engineering packages - for example, the manufacture of a laser measuring machine for high-accuracy roundness measurement of spherical components.

* Wagstaff and Appleton - the machine building division for high-speed packing and packaging applications; particularly successful in the tobacco and pharmaceutical sectors.

* Manthorpe Engineering - a specialist in the multi-axis machining of aerospace alloys.

While the impressive bank of injection moulding machines and scheduled investment in robotic systems in the co-located Manthorpe Building Products Division is undoubtedly impressive - and designed to maintain the group mission of cost-competitive manufacture - it is the Manthorpe Engineering facility that reinforces what 'world class' manufacturing is all about.

Described by Pochciol as a: 'Low profile operation in a very high profile industry sector,' and with clients such as BAE Systems, BPB Gypsum and Rolls-Royce, the Manthorpe Engineering shopfloor is adorned with a host of highly expensive, high-technology machine tools that serve this blue chip, predominantly aerospace-focused, customer base.

Work here includes the supply of various casings for the Rolls-Royce RB211 gas turbine (air intake, intermediate and compressor casings) as well as large high-integrity fabrications for Rolls-Royce engine test facilities.

Indeed, the company recently agreed a further five-year contract with Rolls-Royce Power Engineering for the supply of these casings, in addition to 35 other components.

The latest introduction to the portfolio of machines that produce such high-calibre components is a large-capacity Czech Toshulin SKA 12 two-axis vertical boring and turning machine, supplied by Ward CNC.

The Toshulin's specification typifies an 'outside of the box' purchasing strategy based around installing machines with functionality to further reduce cycle and lead times while at the same time maintaining a clean and pleasant working environment.

All new machine purchases must: * Be capable of multi-axis machining.

* Have high-speed spindles.

* Utilise high-pressure coolant.

* Be supplied as totally enclosed working units to, as a result, eliminate airborne mist.

With maximum swing and facing diameters of 1500mm each and able to accommodate workpieces of 1500mm diameter with a maximum height of 1580mm and weighing 8,000kg, the new Toshulin features a 30-station automatic toolchanger, a maximum cutting force of 44,000N and a rapid traverse rate of 12,000mm/min.

Importantly, and aligning with Manthorpe's continuous improvement edict, the machine's 40kW main motor provides offers table speeds of two to 630 rev/min (compared with the usual 250 rev/min) and was supplied as a self-contained machining cell with 20 bar coolant (with return pump on the swarf conveyor) and mist filtration.

Other machine features include Siemens 840D CNC and four-jaw 1250mm chuck, as well as linear measuring on both X and Z axes.

'We have a lot of confidence in the Toshulin,' Pochciol confirms.

'The new machine - which was especially specified for us, particularly in terms of the table speed - brings our Toshulin VTL tally to three.

Also, one of our main customers uses these machines, and from this perspective it is important that we produce work to the same high standards.' He adds: 'Over the years we have purchased a host of machines from Ward CNC.

Of course, Ward CNC specialises in the types of machines we need in terms of capacity and reliable performance, but we also find it important to work with suppliers that adhere to the same ground rules as us.

Ward has consistently supplied quality products at the right price and backed up with superlative customer service.' With additional investments on the horizon - including another six-figure spend on a single machine - the Manthorpe Group continues its quest to drive down costs through 'working smarter' achieved via machines with faster operating speeds and the capability for increased single-set up working, for example.

And still, Pochciol's views about employee satisfaction are not overshadowed by such impressive machine investments.

'My employees spend a lot of time at work, so it is my duty to make the environment here as good as possible.

At home, they do not live in a mess, so why should they work in it?' The Manthorpe Group's 'people first' policy is also evidenced by the Engineering's Division's apprenticeship programme - which also reinforces how the company has successfully established its 'manufacturing integrator' role with clients such as Rolls-Royce: each year, four Manthorpe apprentices start their induction with a 12-month spell at the aerospace giant's training school.

Thereafter, back at Ripley, the apprentices invariably 'shadow' more experienced operators.

'By year three, these guys are terrific assets - they're invaluable,' says Pochciol.

'And they are essential to this company's continued success.'

A range of multi-tasking CNC machine tools are designed to machine complex components in one set-up and will be shown at the UK's forthcoming Southern Manufacturing 2007 show.


Yamazaki Mazak attendance at Southern Manufacturing 2007 will be used to emphasise the all-round capability of the Mazak CNC machine tool range, which encompasses everything from two-axis lathes, manufactured at its state-of-the-art European headquarters in Worcester, through to the world-leading Integrex series of multi-function machine tools. Actually on the stand, under power, will be an Integrex 100 IV ST multi-tasking machine and a VCN 410A vertical machining centre. In addition, members of Mazak's engineering and sales teams will be on-hand to discuss how best Mazak can improve your productivity.

The Mazak Integrex range is central to the company's 'Done in One' manufacturing system, whereby components are machined complete in a single machine set-up wherever possible.

This system allows lead times to be greatly reduced while at the same time reducing dramatically the value of work in progress, the number of machine tools required and the overall manpower levels.

All of which have major impacts on the bottom line, irrespective of company size.

'Yamazaki Mazak has always been at the forefront of multi-function machine development and the concept of Done in One was originated by us.

We are, therefore, extremely pleased that this concept is now being considered as a cost-effective option for many small- to medium-sized companies.

Our range of machines offers a cost-effective solution to the machining of virtually any component,' said Dr Damien Cleugh, European Marketing, Yamazaki Mazak UK.

Latest turning and milling centres can be specified for even faster and easier shop-floor programming - up to 70% reduction in programming time in comparison to DIN.

The GMX 200S Series linear turning and milling centres from DMG are designed to provide the highest performance for 6-sided complete machining for standard workpieces up to 1185mm in length and 400mm diameter as well as for bar up to 102mm diameter. Key features include an X-axis linear drive, a 6-channel machine bed, a 12,000 rev/min milling spindle with a long Y-axis and an interpolating B-axis. Additional features absolute measuring systems and a 36-tool disc magazine.

Now both the GMX 200S and 250S linear machines can be specified for even faster and easier shop-floor programming - up to 70% reduction in programming time in comparison to DIN.

This introduction makes mill-turn programming as easy and reliable as that for a universal lathe.

When teamed with ShopTurn on Siemens 840D solutionline, the GMX 200S is fully equipped for graphic programming, simple cycle selection and uninterrupted programme monitoring on the shop-floor.

It also provides 3D workpiece simulation for all turning and milling operations extending to the B-axis contour.

This development turns the GMX 200S linear into a highly cost-effective machine for serial production as well as a flexible multi-purpose centre for smaller batches and jobbing work with no limit on geometric complexity.

The GMX 250 linear with its TurnPlus system on the Heidenhain Plus iT controller builds on this flexibility by providing dual channel control for the shop-floor.

It allows the milling/turning spindle and the turret to be programmed with simple dialogue via a menu-based interface.

Features include multi-channel slide display during automatic operation and a detailed machining time readout giving main and idle time.