How long does it take for your CNC machine to stop?

The time a CNC machine runs without the intervention of a craftsman is called autonomy. In other words, the time until your CNC machine shuts down.

Skilled workers are becoming increasingly scarce. To deploy them optimally, you prefer to have them work only on the day shift. To achieve this, you need an autonomy of 16 hours every day. This is because 16 hours is the time between two day shifts. To produce an entire weekend unmanned, you need an autonomy of 62 hours: The time between Friday afternoon 5pm and Monday morning 7am.

Without CNC automation, autonomy is equal to the cycle time of one product. The machine stops, once one NC programme has been run. With CNC automation, autonomy is equal to the series size. In fact, the CNC machine then only stops when the entire series is finished, right?

A problem: Single Batch Automation

Single Batch Automation seems attractive: your operator sets one series and, as soon as the first workpiece of that series comes off the machine 100% perfectly, your operator immediately switches on the robot, which then immediately starts on the rest of the series, while the machine is occupied. Here, at the same time, lies a problem: with Single Batch Automation, the autonomy of your machine is completely dependent on the batch size. This offers several disadvantages, especially for smaller batches:

For small series or single pieces, the CNC machine quickly stops working again, while smaller series are usually the most profitable for your business;
Higher cost per product: with smaller series, fewer spindle hours can share the cost and the cost per product remains relatively high;
Limited flexibility: Large runs ‘occupy’ your machines with production that your customers do not need at all this week. This leaves no capacity for other products that your customers do need immediately this week;
Higher inventories: large series lead to large inventories and financial risks;
Little differentiation: How does your company stand out in a market where high volumes and low prices are the norm?

By sticking to Single Batch Automation, you are missing out on opportunities and incurring unnecessary costs for your business.

Single Batch Automation

Set up one product and produce it unmanned
Autonomy = production time of the set up product

Autonomy: in the above example, the largest autonomy is 10 hours (series 4). Production here runs unmanned, from Thursday 3pm to Friday morning 01am.

A solution: Multi Batch Automation

With Multi Batch Automation, your craftsman ensures that the first workpiece in the series comes off the machine 100% perfectly. Your craftsman does not have the rest of the series produced immediately, but only later – after working hours – by the robot. This gives your craftsman immediate time to set up the next product. And immediately after that, the next one. And the next. In one working day, your craftsman adjusts several small series. Outside working hours, the robot produces all set series unmanned, switching independently to the next series. Indeed, with Multi Batch Automation, the robot exchanges complete fixtures independently. The unique BMO software on the robot cell has also been specially developed for Multi Batch production.

In Multi Batch, autonomy no longer depends on series size. Your craftsmen set up several small series during the day, ensure that each first workpiece comes off the machine 100% perfectly, and let the robot autonomously produce the rest of all series at night and on weekends. This offers several advantages, especially for smaller series:

Valuable work: Your craftsmen add value where it matters most;
Maximum autonomy: unmanned production of multiple small series and single pieces interchangeably at night and on weekends;
Lower cost price: Depreciation, leasing and personnel costs are shared by more spindle hours. This lowers the cost price per product and strengthens your competitive position;
Higher Flexibility: produce only what your customers need immediately and respond quickly to changing priorities;
Lower Inventories: Smaller series lead to smaller stocks and less financial risk;
More Time for Craftsmanship: Fine-tuning products and leaving time to improve processes, programming and expanding craftsmanship. All while robots take over repetitive work;
A healthier business: Lower costs, more flexibility, less stock, faster deliveries, satisfied customers and happy craftsmen who only have to work the day shift.

Multi Batch Automation

Set up several product series first and produce unmanned after working hours
Autonomy = production time of all set up products together

Autonomy: in the above example, the autonomy is 64 hours (series 4 to 12). Production here runs unmanned, from Friday 15:00 to Monday morning 07:00.

Conclusion

With Multi Batch Automation, series size no longer affects your autonomy.

Multi Batch Automation reduces costs, increases flexibility and autonomy, allowing your craftsmen to focus on valuable work while robots take over repetitive tasks, resulting in a more efficient, competitive and healthy business.

Directly to the BMO Multi Batch Automation solutions.

Tailored advice

BMO has been focusing on Multi Batch Automation since 2008. Would you like to discuss what this could mean for your organisation? Then get in touch without any obligation.

Our own in-house machining shop, BMO Precision Parts, is experienced in Multi Batch Automation and runs around 120 spindle hours per machine every week. The craftsmen at BMO Precision Parts work the day shift from 8:00 am to 5:00 pm. We would be happy to give you a tour of our in-house machining shop and tell you more. Of course, you can then also bring your own workpieces and your own craftsmen so that your machining team can experience for themselves what it is like to set up several series in succession in Multi Batch. Our customers call it child’s play to have a BMO robot switch to the next series, unmanned.

We look forward to your visit.