21 Augustl 2007 - Floform gains Q1 status with Ford. Click here to read more...

13 April 2007 - Welsh automotive manufacturer revved for growth following MB. Click here to read more...

15 May 2006 Floform Injects Automation. Click here to read more...

Unmanned operation, cycle time and process capability were paramount for the projects success. With a target cycle time of just 17 seconds per part to achieve the projected quantities of 1 million pieces per annum, Yuasa Warwick Machinery proposed 2 off Takamaz X10i Precision Autoloaded CNC Lathes. The X10i is a single spindle machine with 2 axis servo loaders achieving load unload times of 6 to 8 seconds. To provide the constant parts supply to each machine a main supply stocker and common conveyor were integrated, capable of feeding both machines.

Mr Richards explains, “The conveyor system was designed and configured by Takamaz to allow either machine to run separately and provision has been made for the addition of another machine should production requirements increase above the current levels.”

From past experience of machining the copper injectors Floform recognised the problems that would be encountered with swarf control using a totally automated production system. Partly with this in mind Floform tasked Yuasa Warwick with the turnkey of the project. Both machines were specified with 50 bar coolant systems to assist with solving problems associated with swarf and achieve uninterrupted automatic running of the system. The system was turnkeyed and successfully passed off by Floform personel at Yuasa’s premises prior to shipment and undergoing the same procedure at Floforms production facility in Welshpool.

Floform have always met leading edge quality standards, recognising the need for zero defects. To remove the need for visual inspection of the parts a PICTOR camera systems were machine mounted to monitor finish turned injectors on the out feed conveyors. This system supplied by FS Systems (tel:01933 625162) was set up to inspect the injectors for small amounts of swarf carry over. The camera is triggered automatically as the injectors pass by. Parameters are set to determine the allowable image area and should the part be deemed contaminated then the process is conveniently paused and the operator is alerted.

Commenting on the project Mr Richards says: “ The reliability of first XD8 machines from Takamaz has far exceeded our expectations. This new system has started in the same vane and again we envisage quality, trouble free production. In the first 2 months we have seen efficiency figures over 99% on 24hr running”