The HMCs use a laser eye for efficient broken tool detection during production to minimize the risk of multiple defective parts in the event of a tool failure. After machining is complete, the robot moves the machined part to a deburring station equipped with the FANUC M10. This smaller robot deburrs side one, then the M900 robot flips the part over and the other side is deburred.
The robot then places the deburred part into a high-pressure cabinet. This customized cabinet was designed and built by Renegade, based on input from Stecker Machine, to address all areas of concern. After the washing is complete, the robot moves it to a conveyor belt, where the part is inspected by the operator for bore sizes, critical dimensions and foundry defects. When the part passes inspection, it is reintroduced into the cell and the robot moves the part to the leak tester, which pressurizes the inside of the part for the decay test. If the part fails, it is returned to the operator on the inspection conveyor for further evaluation. If there is no visual evidence of the cause for the leak, it is retested. Otherwise, it is removed from the cell and quarantined for the defect. Parts that pass the leak test are moved to the final packaging for shipment to the customer. The robot will properly orient the part, as well as manipulate the dedicated packaging used between parts to prevent shipping damage.
The entire automation cell is run by a single operator who inspects the quality of the part and maintains tooling is performing as it should. The cell runs two parts per hour and has the capability of running two different part numbers with virtually zero downtime to switch between part numbers. Since implementation, Stecker Machine has noticed that it is scrapping fewer parts and getting more output because of increased consistency in loading and handling of parts, deburring and parts washing.
"As mentioned, this cell is used for precision machining of a large front engine cover for a diesel engine," said Kaeppler. "The output improved by about 25% compared to the larger machines that were used prior to moving into the cell. In addition, the finished product is more consistent due to the part-specific washer and automated deburring."
As for future automation plans, Stecker Machine is looking to continue to utilize robotic cells for high-production jobs or those that require material handling of large parts.
Stecker Machine's philosophy is "Solutions for Manufacturing Challenges." "Stecker works with customers to determine the best and most cost-effective way to address the opportunities that they bring to us," said Kaeppler. "This is accomplished by how we train our employees and giving them the opportunity to provide input, as well as collaborating with suppliers to determine the best solution for a given manufacturing challenge. These resources enable Stecker to react more quickly than other similar suppliers due to our flexibility to assign internal resources to meet the manufacturing challenges of our customers."
Gerald Stecker, a journeyman tool and die maker, started his tool and die business out of his garage with his brother in 1973. They began precision CNC production machining in 1989. Today, the company features a diverse range of CNC machines to meet a wide range of customer requirements. These machines include various sizes of horizontal and vertical machining centers, as well as turning centers. Stecker utilizes robotic technology for part loading, deburring and packaging on several different parts throughout the plant. The company is most competitive on jobs with annual quantities of 1,000 to 100,000. However, prototypes and service volumes are well within the company's capabilities when they are related to production jobs. The shop can machine most ferrous and non-ferrous materials in cast, extruded, plate and bar form, including cast iron, cast aluminum-die, cast, permanent mold, sand cast, austempered ductile iron and cast steel. Value-added services include pressure testing, sub-assemblies, assembly and welding services. Subcontractor relationships have been established to provide other complementary services such as heat treating, painting and coatings that are applied to the castings that are machined.
Stecker Machine's quality department provides exceptional production support, including clear and concise documentation and instructions meeting TS16949 standards, CMM inspection, millipore cleanliness testing, high-accuracy custom gaging, hardness testing, surface finish testing and roundness testing. "We are committed to providing a superior product that meets or exceeds customer expectations," said Kaeppler. "The in-house design and fixture build team provide designs and tooling with short lead times to meet the customers' specifications. Our staff uses the latest modeling, fixture design and CNC software along with constant reinvestment into new technology to remain a leader in the machining industry."