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Fastems_AerospaceAutomationGuide_digital
Fastems_AerospaceAutomationGuide_digital
CHALLENGES
Variables to get right • Do you produce in batches to optimize production cost?
• Do you have significant capital tied in inventory and/or WIP?
• Do you lose orders due to delivery problems?
COST TIED • Do you have scrap or inconsistent capabilities?
PER PIECE CAPITAL LEAD TIMES QUALITY TRACEABILITY • Is your process reproducible?
• Is the history of your delivered parts traceable?
2 3 f a s t e m s . c o m
Status quo: Batch production
Lower cost per piece by making compromises?
Batch production – pros and cons Pro: Lower start cost Con #3: Slower earnings
Batch driven production means producing per part When producing more than what
larger batches of parts than the current order The main reason to produce in batches was ordered, extra capital is tied
PLANNING RESOURCES VALIDATION
backlog consists of. The idea is that the larger is the high production start cost in inventory and revenue realization
the produced batch, the lower the cost per per part. This consists of production becomes slower. There is also a risk of
piece. In the aerospace field where orders are
often recurring, batch production is a natural
planning, start setup, and test drives €€ €€ €€ some parts in the inventory becoming
obsolete, which would mean a direct
to get the part and the quality right.
and its own way a cost efficient choice. That These costs recur every time a new loss.
said, it requires making compromises that are batch is started, regardless of whether
showcased in this spread. the same part has been produced REVENUE IN INVENTORY
• ERP & Excel • NC programs • Setup and
before or not – larger batches mean
• Tools workpiece
€€€ €€€
PROS CONS
less production starts and less
production start costs per part.
• Workholding validation runs
€ €€€
• Raw materials
Lower start cost 1. Higher WIP
per part 2. Longer lead time
3. Slower earnings
Con #1: Higher WIP MACHINE 1 MACHINE 2 MACHINE 3 MACHINE 4
COST PER PIECE
4 5 f a s t e m s . c o m
Full optimization:
Order-driven production
ORDER-DRIVEN PRODUCTION Economical order-driven
ECONOMICALLY production
To lower the cost per piece, many unit cost of producing a single piece
COST PER PIECE, BATCH OF 1 COST PER PIECE, BATCH OF 100
manufacturers are used to producing is the same as when producing
in larger batches. This is because a batch of 100*. Not only is the unit
in the past small-batch production cost lower, order-driven manufacturing
€€€ €€€
has not been economically feasible.
Luckily, today’s technologies offer
a variety of possibilities to optimize
also frees capital from WIP
and inventory, and allows just-in-
time deliveries with shorter lead times.
€ €
production to be economical for Automation also enables effortless and
batches of all sizes, meaning that the first time right traceability reporting.
WHAT DOES IT MEAN
IN PRACTICE?
*In some specific cases the batch
manufacturing may be still more reasonable There are two steps that are needed to On the next page we introduce
than order-driven manufacturing, ie. if there achieve order-driven and economical an example shopfloor the most
are destructive tests or hardening included production: (1) optimization of common bottlenecks
in the process.
the key production bottlenecks, that require optimization to
From batch production and (2) making the production achieve order-driven economical
to order-driven production process repeatable. This requires production. After that we dive deeper
looking at the whole production and in each of these areas, introducing
COST PER PIECE
MACHINE(S)
MACHINE(S)
TURNING
MILLING
setups between the process phases, to optimize all of the listed
(5) process tracking, and (6) machine bottlenecks gradually or at
tools. once, and flexibility also refers
5 to the automation system being
QUALITY AND 3 extendable for future needs.
TRACING TOOL
MANAGEMENT
Which are your production
bottlenecks?
FINISHING
SURFACE WASHING
4
TREATMENT CMM TRANSFERS
& LOADING
8 9 9 f a s t e m s . c o m
1 Production planning TYPICAL CHALLENGES
• the production plan changes
all the time due to incoming
orders and priorities
Challenges in manual production In contrast, with flexible automation The intelligent production control • unexpected changes
planning (ERP + Excel) are typically an intelligent production control fetches real-time information from in production
related to poor visibility and changes. software is integrated seamlessly to the different data systems and machinery, • lead times are hard to estimate
The production plan is laborious different data systems and production and calculates the optimal production and promises made to the
to make manually, and even more equipment. Now, production can be schedule for incoming orders. It customer are difficult to keep
laborious to keep up-to-date when planned ahead based on real-time: automatically updates the production
new, high-priority orders come in or plan when a new order comes in and FLEXIBLE AUTOMATION
the unexpected happens in production. • Order information with delivery warns in advance if a resource is BENEFITS
The unexpected meaning anything from dates from ERP missing and an order is about to get
missing raw material to a breaking tool, • Information of available delayed. • the production plan
labor shortage, sudden maintenance machinery and resources After production, the intelligent automatically updates based
break or previous orders taking longer (NC programs, workholding, control software reports the completed on real-time information
than expected to produce. tools, raw materials) jobs back to ERP. received from data systems and
With flexible automation and machinery
the intelligent production control, • flexible production: minimize
resources can be shared between the negative effects of machine
different machine tools, meaning that breakdowns and resource
parts can be produced with any suitable shortages by removing
machine tool that has free capacity machine dedication
– not only with a dedicated one. • visibility over production and
This can significantly reduce WIP, upcoming resource needs
shorten lead times and increase • information of order completion
capacity utilization. available even months ahead
WHAT TO CONSIDER?
The intelligent
To achieve flexible production
production control planning, make sure your
updates the automation has the following
integrations:
production plan • ERP
• machinery, regardless
Intelligent production
when a new order of machine brand(s)
control software
schedules
comes and warns in • CAM
• Product Data Management
the production based advance (PDM)
on ERP order
due dates, and if a resource • Tool Data Management System
adapts to any
changes in real time. is missing.
10 1 1 f a s t e m s . c o m
2 Production Start Setup COMMON CHALLENGES
• production is driven by
the easiest available setup
instead of the importance
Manual workpiece set-up changes manufacture next might be made and needed raw material. All these of orders
take a lot of time, even with automatic based on the easiest available setup resources are easily available when • poor reproduceability sets
pallet changers (APC). The key at the time, as opposed to choosing needed. If some resources are missing, challenges for standardizing part
problem is that the manual setup the order that is actually most critical to the system will inform about shortages quality
work is difficult to restore – in the complete. In a way, production might in advance to avoid unnecessary • setup work decreases utilization
worst cases setup work needs to be being driven by setups instead of production stops. and production output
be started from scratch every time, orders. To reduce machine dependent
even when producing recurring In case of recurring orders, flexible jobs, the system can bring the same FLEXIBLE AUTOMATION
parts. Even with the best possible automation system has setups pre- data and resources into any of BENEFITS
documentation, it takes extra effort configured with a systematic approach the parallel machine tools on
and time to start and complete to manage all the information related to the shopfloor, no matter if the part • the system makes sure
manual setup work. Because of setups in production. This information has been previously machined with the everything is in place before
the labor-intensive nature of setup consists of NC programs, cutting same machine or not. starting the production
work, deciding which parts to tools, workholding, work instructions Pre-configured setups mean that • if a resource is missing, the
every item, starting from the first, operator will know in advance
can be run at 100% speed with and have time to react
Manual vs automated setup the same quality. The operator only • setup time shortens significantly
needs to take care of the clamping of or goes down to zero
the parts. This usually means improved • setup is available for any
work ergonomics. Part clamping suitable machine tool
Get the needed Find suitable
tools, measure, workholding can also be robotized when annual
input tool data components and
production volumes get larger. WHAT TO CONSIDER
to a machine tool, clamp them to
put tools in the machine tool If you want to minimize setup
the magazine
times in your production, make
sure your automation is capable
AUTOMATED of:
SETUP • fetching and sending information
MANUAL Bring DURATION: to machine tools (any brand
SETUP the needed FROM SECONDS on your shopfloor)
raw materials TO MINUTES
DURATION: FROM • fetching NC programs from CAM
TENS OF MINUTES TO
HOURS, EVEN DAYS Clamp • saving the workpiece
workpieces instructions related to setup
• storing the list of needed tools
and possibly tool offsets
Setup and workpiece
validation after Automation brings the right NC programs, • handling the raw material
the first run(s). Get the needed workholding, raw materials and tools to logistics
This is an iterative NC program and the machine(s) with all the needed data.
process and might download it to The quality and production speed are • having an interface with AGVs
require multiple runs. the machine tool high from the first run. (in case they are in use)
• storing workholding hardware
12 1 3 and all informationf arelated
s t e m sto. cito m
3 Tool Management CHALLENGES
• machine downtime because
of tool shortages
• high manual intervention and
When the red light of a machine tool and integrating a tool presetting device end, the system automatically brings planning to keep machines running
starts blinking, it is often because of a to the production control software a replacement from a centralized tool and tools up-to-date
tool shortage. The required tool may and machine tools, the tool presetting storage. The reduced need for sister • risk for human errors in tool loading
be completely missing or it has run process can be greatly streamlined. tooling, ability to share tools between and offset writing to machines
out of tool life. This is a daily situation This also removes human errors in the machines and having a proactive • high tool and machine magazine
on the shopfloor – tool shortages tool presetting process. way of maintaining tool life bring investment
are among the biggest time thieves In aerospace manufacturing where great utilization improvements while
in production, constantly stopping the materials are challenging, tool generating savings in tool investment. TOOL AUTOMATION BENEFITS
spindles and requiring action. lives short and the mix of machines Removing manual tool movements
Different software and/or hardware and tools often high, tool maintenance also improves the working ergonomics • know in advance which tool
solutions can streamline tool plays an even more important role. of the operators. is needed, where and when
management. The first step of tool With more flexible tool automation, If the tool lives are extremely short • save time in tool setups
automation is a production control tools can be shared with different and demand for renewed tools is high, • no machine crashes due to
software integrated to the machine machines and delivered automatically tool automation can be extended to wrong tool loading
tools, telling which tools are needed into machines based on real-time optimize the tool setup process (insert • tools can be shared between
in which machine and when. By using needs. When the tool life is about to changes and presetting). machines -> less tools needed, less
machine tool dedicated work, longer
lights-out manufacturing periods
TOOL AUTOMATION GRADUALLY • improved health and safety related
DRIVERS TO IMPROVE to tool maintenance
TOOL MANAGEMENT 1. From reactive to proactive
1 In-advance reports on tool needs: WHAT TO CONSIDER
1. Difficult-to-cut and 2 which tool is needed, where and when
expensive raw materials • integration with machine tools
2. High mix 2. Remove errors from tool loading and/or presetters of any brand
3. A lot of machines Tool presetter and automatic input • integration capability with different
4. Expensive and of tool presets to machine tools tool data management systems
customized tools • when adding a centralized tool
3. Remove machine dedication
5. Health and safety risks storage, think about efficient
and reduce need for sister tooling
due to heavy tools floorspace usage, also vertically
Tools stored in a centralized tool
and repetitive tasks 3 • make sure your tool automation
magazine and robotically transferred
solution is extendable for future
to machines based on real-time needs
needs
(a tool can be shared between many
machine tools)
4
4. Save time from tool setups
Automated tool setup process
5
including insert changes, washing
and presetting
14 1 5 f a s t e m s . c o m
4 Workpiece transfers CHALLENGES
• waiting time between process
16 1 7 f a s t e m s . c o m
5 Quality, Traceability CHALLENGES
• demand for full part traceability
18 1 9 f a s t e m s . c o m
6 Machine tools SHORT-VIEWED MACHINE
INVESTMENT MAY LEAD TO
• dedicated machines
– what happens when
The machine selection process thought out before hand. In addition, In which size of an envelope a machine breaks?
starts from the parts or part families in the ideal world you would want to would all of your parts fit? • an increased investment need
that are produced. Oftentimes previous make sure that all machines are able Do you need many envelopes? for machine tools
machine investments have been made to produce any of the parts. Benefits • increased floorspace needs
based on the machining needs at the of purchasing similar machines that D • tool setup challenges when
time, as opposed to also planning are able to run as many parts as sister tools are in use
ahead. In the future, this can then result possible give flexibility in job resourcing
in a situation where machines are not by removing the dedicated machines, WITH GOOD INVESTMENT
suitable for new parts, and the need in operator resourcing by making sure PLANNING
for new machines arises yet again. everyone can use any machine, and W
H • the long-term investment
There are many shopfloors that are reduces the maintenance and sparepart
full of different machine types, each costs. Also the amount of clampings for machine tools and
producing dedicated parts and having need to be thought out: in general, the maintenance costs reduce
specialised operators. Sometimes it 5-axis machines give greater flexibility • operator resourcing
is the best way to go, especially with with a reduced need for reclamping. becomes more flexible because
different raw materials and variable Hard materials cause a large more people have skills
THINK ABOUT to run the same machine
part sizes, but oftentimes one machine consumption of cutting tools. This YOUR MACHINE TOOL
could produce many more different should be considered when deciding the • the floorspace is better utilized
RESOURCING with less tools that are all
parts than it is used for. tool magazine capacity of each machine
• do you need dedicated capable of performing as many
When planning a machine tool tool. A big enough magazine allows for
machines or could you utilize jobs as possible
investment, the future business sister tools that enable longer lights-
the “envelope” model to
possibilities and resource- out manufacturing periods. However, if
improve machine utilization? WHAT TO CONSIDER
efficient production should be tool life is short and there are many
• when a machine breaks or
also considered. The range of part machine tools, tool automation with one • similar machines to increase
an operator is on vacation,
sizes, the “envelope” in which all centralized storage for thousands of flexibility and reduce
do you have similar
produced parts fit into, need to be tools and the ability to share and bring maintenance costs
machines or people with the
tools to machines can be a profitable • 3-, 4- or 5-axis machine, what
right skills to substitute?
investment (presented in section 3).
Similar machines • is it better to save on
is suitable for your current and
future needs?
machine costs and increase
that are able to run the amount (and time)
• large enough tool magazines
to also enable the utilization of
as many parts of clampings or the other
sister tools / tool automation
way around?
as possible • what is your tool and
to share the tools for different
machines
give flexibility in sister tool need – should
• machine interfaces for
you purchase larger tool
resourcing and reduce magazines or a centralized
integration with different
production data systems
maintenance costs. one?
• operator skillsets on machine
control technologies
20 2 1 f a s t e m s . c o m
Summary CHECKLIST – REQUIREMENTS TO CONSIDER
WHEN PLANNING TO AUTOMATE
business can be
automated process AS9100
compatible? We at Fastems are
■ integration with machine what are the most suitable for your
tools and different tool data current and future needs?
remarkable.
happy to help solve any productivity management systems ■ tool magazines large enough to
challenges: fastems.com/contact
■ tool presetter and integration to it also enable utilization of sister
■ when considering tool magazines tools/ tool automation to share
or one centralized tool magazine, the tools for different machines
efficient use of floorspace, also
vertically
COST TIED
PER PIECE CAPITAL LEAD TIMES QUALITY TRACEABILITY
22 2 3 f a s t e m s . c o m
Read how aerospace and
defense manufacturers have
solved their productivity
challenges with automation:
fastems.com/aerospace