Operator evolution

By spinning-off Rodmatic Hytek, a high technology subcontract machining division with a smaller batch capability, from its more traditional volume production operation Rodmatic Multico, Reading based Rodmatic has been able to put a foot firmly in both camps and not only provide a high production solution using the traditional mechanically driven multi-spindle automatic lathe but also a fast turnaround, small batch supply using CNC. 

As a result, existing customers have been taking advantage and increasing the size of Rodmatic's order book for smaller quantities and totally new customers have also been drawn in due to the flexibility of supply for larger volumes of parts and coupled with the ability to react with shorter leadtimes when needed using CNC.

This has helped managing director Brian Steatham to progressively draw in business that was previously being ferried to low cost production areas overseas. “By adapting and integrating the services provided by the two divisions we now have total flexibility to respond to almost any needs,” he says.

“Rodmatic Multico, for instance, still runs its 38 mechanically driven multi-spindle autos, which have capacity up to 80mm diameter to provide around the clock production of something like 1 million parts a month. He now finds the CNC division running through the night as well, but often under unmanned production conditions.

However, moving the business into high technology did not happen overnight – it took careful planning and organisation and Mr Steatham put training and retraining as high on the agenda as the commitment to new plant purchase. Reflecting on the decision he remarks: “This has certainly paid-off with batch times being progressively cut to almost half compared to 18 months ago and setting times, cycle times and plant utilisation graphs now bear no comparison.”

He continues: “Rather than recruit, we decided to retrain some of our multi-spindle setters and an optical profile grinding (OPG) operator in CNC technology but were very concerned in converting their ‘spanner twisting' mindset into one of pressing buttons and gazing at screens. However, after the initial trials and tribulations and a steady growth in confidence, they responded in a way we could never have predicted to take on the new responsibilities.”

Over the past three years Rodmatic Hytek has progressively installed a 5-axis Daewoo Puma MX 2000ST turn/mill centre, two Daewoo Lynx fixed head, turn/mill centres and two Star 9- and 7-axis sliding head lathes. These are all supported by a programmable via PLC component cleaning centre, a CNC coordinate measuring machine, and a programmable non-contact, video-based measuring centre. According to Mr Steatham, the retraining for the Star sliding head turn/mill centres with the assistance of Part Maker CAM programming was the most challenging task as each setter had to completely rethink his method of working – especially with sub-spindles, balanced cutting cycles and overlapping of tools.

Both latter activities are common on multi-auto set-ups but on sliding head machines it makes a significant difference in competitive cycle times. “There are a multitude of very innovative practices and process dodges built-up over the years by the setters which are effectively the ‘skills' behind making a multi-auto really productive,” Mr Steatham reveals. “It is this skill base that has now been introduced very successfully to our CNC operations on higher value components.

“We now supply a much wider group of customers with large number of complex parts in batches that range from a few dozen to several thousand,” he continues. “The difference is these now involve extensive changeovers and new challenges. It is the number of resets that keep the setters on their toes and creates for them totally new levels of interest having to agree plans with production control on a regular basis to achieve the best use of machines, materials and tools. Additionally, the single cycle philosophy now involves a significant amount of milling and totally different materials which now includes a whole raft of stainless steels and materials such as EN 24T.”

With the constant demand for re-setting machines at Rodmatic Hytek, regular training updates with machine and tooling suppliers has been the key to keeping up with technology, developments and techniques. Concludes Mr Steatham: “Not only are we finding that we are attracting new customers, but we are significantly increasing the rate of converting enquiries into orders, which gives a huge boost in confidence and confirms to everyone involved we are on the right path.”

Rodmatic
www.rodmatic.com