What is the Advantage of Process Integration?
In recent years, the importance of process integration has been emphasized at production sites due to the labour shortage problem, aging workforce, shortage of skilled operators and engineers. This shortage is caused by generation change and reduced number of workers in the industry due the heavier operator’s workload. In many cases, a single operator must take care of multiple processes. Inevitably, the operator must learn many skills and operate several machines and many operators struggled under its heavy burden. Current many companies are facing a difficult situation regarding skilled operators.
Process Division vs. Process Integration
To solve such burdens, process integration has been gaining attention worldwide. Process integration consist in combining multiple processes into one, especially in the production field, where various processes using various machines are integrated into a single machine, and in many cases a multitasking machine. A multitasking machine is a numerically controlled machine tool with an automatic tool change function (including turret type). It can perform various machining operations, such as milling and turning, without setup. The most important feature of the multitasking machine is that it can complete multiple processes with a single machine. Especially if it has two spindles, it is possible to machine from a blank material to finished products and it is the ideal machine tool for achieving process integration.
The opposite of “process integration” is the term “process division,” which refers to separating process by operations. We want to explain the difference between both production systems.
Advantage of Process Integration #1: No Need for Transportation
Process integration has four major advantages: The first advantage is no need for transportation. In the case of process division, work-in-progress products (WIP) must be transported to the next machine every time a process is completed on the first machine. Operations like re-clamping and re-positioning become necessary. This workflow takes time, even for an experienced operator. If the number of products is small, it could be fine. However, when it comes to a larger number like 100 or 200 parts the required man-hours can be considerable high. The workload of loading and unloading WIP is also tough. With a multitasking machine, the man-hours required for transportation are zero.
There is another concern. In the production line with the process division, a waiting time occurs if a post process is not finished, even though a prior process was completed. In many cases the efficiency is not constant and man-hours required will be larger than expected. With a multitasking machine waiting time does not occur because all machining processes are carried out in one machine. Compared to the process division, the process integration guarantees a smooth production flow.
Advantage of Process Integration #2: No Work-In-Progress Products (WIP)
The second advantage is no work-in-progress products (WIP). As mentioned above, in process division, re-clamping is always required. Each time after re-clamp repositioning is also needed and those processes are time-consuming especially if the operator is unfamiliar with the process. The accuracy may vary depending on the operator’s fatigue and skill set, making it difficult to process the same operation with the same accuracy, reducing efficiency. Also, a place to store the WIP is necessary, which needs a surprising amount of floor space. With a multitasking machine WIP is NOT generated, because one machine will process from a blank material to finished products. Above all, there is no re-clamping and re-positioning the part by the operator, making the process efficiency much higher. And also improving the accuracy variation caused by the operator’s fatigue and or experience.
Advantage of Process Integration #3: Reduction of Operator’s Man-Hours
The third advantage is the reduction of operator man-hours. In either the process division or the process integration, the setup including tool selection and clamping (jaw processing) is required before running the machine. With the process division, the setup must be performed for all machines in the production line. If the factory has four machines to produce a product, they need setup time for four machines. Then, what if the factory is demanded to change the products frequently? It often happens due to fluctuating demand or high-mix low-volume production. In this circumstance, the setup process needs to be repeated many times. The setup of many machines will use more setup time increasing the required operator’s man-hours. With a multitasking machine, only one setup is required. Even if the products are changed frequently with a multitasking machine that operation will be more flexible because can be done by simply changing the setup of this one machine.
With the process division, another reason to increase the man-hours is the pick-up and load time of WIP. Even after the machines start running, the operator cannot leave it easily because they need to pick up and load WIP regularly and also is tough for one operator to set up several machines one by one. In the process integration with a multitasking machine, the entire process is performed from a blank material to finished products in one machine and there is no need to stay in front of it constantly. The multitasking machine cuts the burden of the operators on the shop floor.
Advantage of Process Integration #4: Space-Saving
The fourth advantage is space-saving. With the process division, each process needs a machine. Therefore, more machines and floor are required compared to the process integration with a multitasking machine. Even if each machine is smaller, it inevitably takes up more space when all machines are lined up. Compared to general-purpose or dedicated machines, a multitasking machine is larger, but because all processes are integrated, it requires smaller space at the end.
Thus, the process integration with a multitasking machine has four advantages: “no transportation,” “no WIP”, “reduction of operator man-hours” and “space savings”. Of course, we are not denying the process division. The burden per process becomes smaller and simpler by separating each process and which could be profitable depending on the production system. However, process integration is a strong alternative for solving the labour shortage problem and providing a flexible production system.
SC-100X2 – The “Born to be fast” Multitasking Machine Enabling Superimposed Machining
The SC-100X2 is a twin-turret twin-spindle multitasking machine in a 6” class that enables superimposed machining. This machine is a gateway for multitasking machines with a compact and space-saving design. With this machine, you can combine processes of at least 2 x CNC lathes and 1 x machining centre. While the lower turret is fixed, the upper turret has XYZ-axis, and moreover, the right spindle has X and Z-axis, which means this machine has two X-axes. This is why it was named SC-100X2. This machine drastically reduces the cycle time.
For More information, contact WD Hearn – Tel: 021 534 5351
