Rapid response

With a global reputation for supplying medium to high volume precision engineering components Mini Gears operates from a 35,000ft² production facility in Stockport. From here the company has committed three Mazak Integrex multi-function machine tools to support the new division. Manufacturing director, Peter Durkin, explains: “We have a number of years experience using Mazak's ‘Done-in-One' machining philosophy to maximise the efficiency of these machines on our higher volume production runs. This experience is now being applied along with our manufacturing engineering knowledge to provide a manufacturing service that has been designed to meet the current needs of the engineering sector.” To support the requirements of various industry sectors for smaller batch sizes of precision machined components the management team at Mini Gears has invested in the latest machine tool technology as well as the support infrastructure needed to get the spindles turning as quickly as possible. Company chairman, Paul Darwent, says: “Quick Response Manufacturing (QRM) is a companywide strategy to cut leadtimes in all phases of manufacturing and office operations. It can help bring our customers' products to market quicker, securing their business in a rapidly changing manufacturing environment.” Across the shopfloor the workload is prioritised by the company's EFACS manufacturing system. All components destined for the QRM division are programmed offline and the NC code is transferred to the machine's Mazatrol controller via a DNC link or with a secure flash drive. Mini Gears' engineers have carried out an extensive tool rationalisation analysis program and, as a result, all three Integrex machines – two 300-4st and a 200-4s – are loaded with 24 common tools as well as Renishaw probing. Any job-specific milling, turning, drilling or process specific tools required can simply be loaded into the remaining tooling locations. Using this procedure the company can typically start cutting metal in just 30 minutes. Mr Durkin adds: “The inherent quality of the machines equipped with the parts probing allows us to work to tight tolerances, down to ±0.0063mm and, from proven experience, we know that one hit machining can significantly reduce leadtimes and provide a 20% cost saving on average.” Although the new division has been established to provide an expedited service, Mr Darwent is quick to point out that it is not a rapid prototyping service. “The QRM division is ideal for batches of between five and 50, and the more complex the finished component the more beneficial the service will be to the customer. It is ideal for companies operating on a minimal stock level that want a secure supply, or for businesses that have been let down at the last minute by existing suppliers,” he concludes. Mini Gears
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