b'Methods Machine Tools Helps World Class Automotive Manufacturer GrowVia Full Complement of Machining Solutions and AutomationSUMMARY Gil-Mar Manufacturing was experiencingareinthehigh90swithKIWAvs.thepart sets are made per 10-hour shift.intoPartnering for Success hassavedgreat distributor that stands behind the growingpains.Themanufacturerhasmid-80s on our previous machines, heItwasaverysuccessfulproject,MethodsMachineToolsequipment they sell, said Joe Ruicci, been machining, fabricating, and weldingsaid. Our part quality has also greatlyandforus,aparadigmshiftGil-MarhundredsofthousandsofGil-MarsCOO.Forourcompany parts for Tier 1 automotive suppliers andimproved. automationfromdedicated,dollarsthroughtheirinnovativeto grow and flourish in the future, we thedefenseindustryformorethan30Sincebeingintroducedtotheirfirstindividual equipment, LaVigne said.solutions,programmingstrategies,need strong experts such as Methods COMPANY: Gil-Maryears. With three plants outside of Detroit,KIWAhorizontal,Gil-Marhasadded16The cell exceeded all goals for thereducedcycletimes,andthat possess the strategic strength and Manufacturing, Inc.,Mich., and more than 120 machines, theKIWAstotheiroperation,comprisedofF-150 door hinge contract, providingincreased throughput.vision to help transform machines and headquartered inshop was having trouble keeping up with14 HMCs and two VMCs, a testament toa lean solution with tight tolerances. It is a fantastic relationship with ametal into business success.Canton, Mich. demanding jobs and volumes. howproductive,reliable,andmission-Average machines, lack of suppliercriticalthesemachinesareinGil-Mars PROBLEM: The Tier 1expertise,andmediocreserviceandmanufacturing operation.automotive suppliersupport led to increased downtime and was experiencinglosses,PlantManagerDaveLaVigneRoboDrill Cell: Taking Automation to unprecedentedsaid. Around 2008 into 2009, it becamethe Next Levelgrowth. Gil-Marspretty clear to us that we really neededInlate2014Gil-Marpresentedan needs were evolvingtoalignourselveswithahighlyskilledopportunity to manufacture door hinge rapidly. Subparmachinetoolsupplier,hesaid.Wesets for the Ford F-150. But Tier 1 supplier service/supportnot only wanted leading machine toolMidway Products Group, Inc. demanded and middle-of-the- technologyandservicebutalsotheahighoutput-premiumvaluesolution. road machines werevision to help us automate and integrateWe saw this as a large cradle-to-grave holding the companymachinesandsystemsasawholetosolution that Midway wantedvery fast, back and contributingenable smart manufacturing solutions. repeatable,reliable,andaffordable, to a greater amount Gil-Mars search didnt take them long.LaVigne said.of downtime. Methods technology center in nearbyThecompanyagainapproached Wixom, Mich., provided the insight andMethodstodevelopasolutionforthe SOLUTION: Thehorsepower for Gil-Mar to take notice.program.company investedItmadecompletesenseforustoWithascopeof180,000parts in multiple solutionsgiveMethodsthenod,LaVignesaid.timesfourdoors,andon-demand throughout the years,Theyhaveleadingmachinebrands,delivery and cost a key consideration, including fast, preciseexcellent integration abilities, applicationautomationwasessential,said KIWA machine toolsengineering,service,andsupport,andThomas Saur, Methods Vice President and custom are only 15 miles away from us with aof FANUC America Products.RoboDrill cells. warehouse full of parts and machines.Methodsdesignedacustom,lights-outcellcomprisingsixfour-axisFANUC RESULT: Gil-MarKIWA: A Horizontal Shift RoboDrillD21LiA5machineswith achieved a 20In 2009, Gil-Mar wanted a serviceable,30-tapers, two FANUC robots, and infeed percent increasehigh-value workhorse with a good trackandoutfeedconveyors.Inthissystem, in throughput andrecord.Thecompanyrecognizedthetwooperatorsloadductileironblanks improved uptimes withgreater proportions of breakdowns andontoinfeedconveyorsthatfeedtwo the KIWA machineslackofservice/supporthadbecomeoperations: milling/drilling as well as spot and significantly lowerunmanageable. contouring and spot facing. Finished parts cycle times thanks toLaVigne was impressed with the frame,are then loaded onto outfeed conveyors automated RoboDrills. casting, and speed of the KIWA KH-45. forinspection.Productionoutputissix Wehaveachieved20percentminutes per cycle (three minutes per part, increasesinthroughput,anduptimesmachined two at a time). Typically, 325'