We had complex machining operations which required several processing steps on our Transfer Machines, including long and complicated setups.
Furthermore, at a qualitative level, it was not always possible to obtain the best result, especially considering the risk of performing manual deburring operations.
Thanks to the Flexible Production Method, it is possible to combine the processing operations and this allows us to work on even very complex pieces in a single clamping, with simpler and faster setups, even eliminating any subsequent deburring problem.
Again, thanks to the Flexible Production Method, we have considerably reduced the lead-time of items that were previously processed on Transfer Machines in several operations, even though sometimes the cycle time may be higher.
However, this problem has been solved by having the parts immediately available and by the fastest setup times.
Furthermore, the quality of pieces produced with this Method is significantly improved, eliminating deburring issues and the quality issues that come with them.
Via Per Alzo 39 – 28017 San Maurizio d’Opaglio (NO)
Our production includes a significant number of different items and lots ranging from a few to tens of thousands of parts.
For production we mainly used machining centers for medium-low lots and transfer machines for large lots.
These choices were not sufficient to adequately cover our wide range of needs and, especially in the mid-range of the series, the results were not satisfactory.
Thanks to the use of Flexible Production and of the Flexible Machine we have improved our production; improving productivity, reducing set-up times and guaranteeing the flexibility we need.
After a first initial experience, we quickly installed a second MULTICENTER Flexible Machine.
Bonomi Eugenio S.p.A.
Via A. Mercanti,17 25018 – Montichiari, (BRESCIA)
“We had a horizontal machining center and were unable to deal with the work load due to high volumes but relatively small lots, so in order to solve this problem we would have had to purchase two additional machining centers, which also meant having to hire more personnel to operate the machines.
Then we discovered the Flexible Production method!
We were able to move all the milling jobs to one machine, since the processing time per piece was reduced.
The main advantage was without a doubt the fact that, with the same number of operators, we managed to deal with the work load, without hiring other technicians.
Once a piece is tooled the first time, the following set ups are quick and easy.”
Mr. Arno Drechsel
Julius Durst Str. 10
9900 Lienz – Austria
“I had cycle time problems due to dead times of the tool changes and part load. In order to have all machining completed on the part I had to tool different machines.
Now I load the part on the free pallet while the units are machining.
The positive results are a considerable reduction of the production times, precision and reduction of the set up times.”
ING. MARCO STRADIOTTI
“The problems we had before were mainly long set up and cycle times. Let’s say that once we had found the balance, we tried to machine as much parts as possible increasing the inventory (a great cost for the company).
Now I got more precision, reduction of set up times, reduction of cycle times, flexibility in product change. This allows us to meet our Customer’s requests as much as possible.”
Here you find an e-mail with some questions that a potential customer, who was interested in purchasing our machine, wrote to a customer that already used our machine.
Here is the original version and what they said…
To: Mike Heiny
Subject: Machining system
We are considering to buy a MULTICENTER from PORTA and you are in their reference list. I was wondering if I can find the right time to contact you. I would like to discuss with you the following questions:
HOW WOULD YOU CONSIDER YOUR PURCHASE FROM PORTA?
Answer: the experience of purchase with Porta North America Inc. was positive. They are a first-class organization.
WERE YOU SATISFIED OF THE INSTALLATION?
Answer: Very satisfied. The installation and the support was outstanding.
HOW LONG IS IT SINCE YOU HAVE THE MACHINES?
Answer: I bought them and got them installed in 2011.
DID YOU PURCHASE A TURNKEY SOLUTION?
Answer: Yes, the machines were tested in Italy and then again at Amron.
COULD YOU DESCRIBE THE DOCUMENTATION YOU RECEIVED WITH THE TURNKEY SOLUTION?
Answer: Two handbooks with codes, detailed drawings and electrical plan and any other information that you could need.
DID THEY SUPPLY YOU ALSO THE AUTOMATION?
Answer: Automatic load and unload, Amron was responsible for bringing the raw parts to the machine and move the finished ones.
WERE YOU SATISFIED OF THE REAL CYCLE TIME IN COMPARISON TO THE ONE CALCULATE IN THE QUOTATION?
Answer: The first machine tool company that gave us what was calculated in the quotation.
ARE YOU SATISFIED OF THE TRAINING FOR THE PROGRAMMING AND MAINTENACE OF YOUR OPERATORS?
Answer: Great training and on-line support, Art and Kevin from Porta North America are good in this.
ARE YOU SATISFIED OF THE SERVICE?
Answer: The service is very good, we work together and they are very reactive. We needed them only a few times, Porta North America made sure to modify their programs and was at disposal in case of need.
WOULD YOU ORDER AGAIN?
Answer: Yes, we are considering other 3 machines in order to replace the existing ones.
Amron, Division of AMTEC
920 Amron Ave.
Antigo, Wisconsin 54409
“Before I had to machine the part in different clampings with the following problems:
- CRITICAL THICKNESS ACCURACIES
- BURR PROBLEM
Thanks to Flexible Production Method we had the chance to optimize the cycle in order to solve the problems of quality and cycle time.
In addition, now we can tool from one part to another in 15 minutes thanks to the great availability of ever-present tools in the magazine. Actually the changeover consists only of a simple jaw change.”
CAVAGNA GROUP S.p.A. – Divisione OMECA
Via Statale 11/13
25010 Calcinato (Ponte San Marco)
BS – Italy
Owner – Technical Director:
“It was impossible for us to machine the six “sides” of my piece, also with a few angle holes, at the same time.
Now, I can machine the six “faces” and use standard tools.
Thanks to Method Flexible Production I solved problems with the machining of some families of pieces with execution times that finally allow me to speak of “Productivity”.
Owner – Technical Director
F.lli Tognella S.p.A.
via Goito, 60
21019 Somma Lombardo (Varese) – Italy
Owner and Managing Director
“We have cut down on scrap, we are able to deliver much faster and we have reduced our production costs thanks to the quick re-tooling.
In addition, we have achieved positive results, improving the quality of our finished pieces and increasing productivity.
Today we can offer our customers faster deliveries at a more competitive price!”
Dr. Alexander Ostertag
Owner and Managing Director
IZ-N.Ö.-Süd, Straße 3, Obj. 35
A-2351 Wiener Neudorf – Austria
“The parts we machine are parts that are usually machined on horizontal machining centers.
On a machining center, in order to compensate for tool changes and have a reasonable cycle time, I put more parts on each fixture. This created problems of repeatability as they are forged or cast parts.
The advantage now is the possibility of load and unload with robot that with a machining center is not possible unless you invest more than 20/25 times the amount for the fixture cost. As a consequence there is an important reduction of personnel.
The flexibility of managing the ramp up and down of a part, i.e. before a part is regularly machined on a transfer there are smaller batches and pre-operation to do that on a transfer cannot be handled with low costs like today.”
Via Angelo Gitti, 18
25060 Marcheno (BS) – ITALY
Production & Lean Manager
“Today we can think and operate small batches using the department logic and not single machine logic… Therefore, I do not have to stop big orders in order to make place for smaller requests anymore because now I apply the Flexible Production method.”
Production & Lean Manager
OMB SALERI, SpA
Via Rose di Sotto 38/C
25126 BRESCIA – ITALY
“I made the right choice since I found the right compromise between “PRODUCTIVITY” and “FLEXIBILITY”.
We have different parts that are machined on your machine with batches which sometimes are small (500/1.000 parts) and sometimes larger (15.000/20.000). Before these parts were produced by single machining centers or by a twin spindle lathe.
We found out that now the set up times are similar to the previous machines but the productivity is immediately FIVE TIMES BETTER than the previous one (from annual statement).
We appreciate your fixture design and your project.
Your project allowed us to realize the part clamping in an extremely functional and performing way.”
Ing. Carlo Medina
Via dello Strego, 1
28010 Cavallirio (NO) – Italy