Project
PRJ-0264
Industry
Metals & Fabrication
Application
CNC machine tending
Commissioned
Mar 7, 2025
Status
Commissioned
Spindle utilisation raised from 54 % to 81 % by running both lathes through an unmanned night period.
Project
PRJ-0264
Industry
Metals & Fabrication
Application
CNC machine tending
Commissioned
Mar 7, 2025
Status
Commissioned
Spindle utilisation raised from 54 % to 81 % by running both lathes through an unmanned night period.
FIG. 1
CNC machine tending
PRJ-0264
01
Commissioning results
Measured outcome
01
Commissioning results
Measured outcome
Spindle utilisation
54
→
81
%
Average of 2 lathes · 8 weeks after SAT vs. 8 weeks before
Spindle utilisation
54
→
81
%
Average of 2 lathes · 8 weeks after SAT vs. 8 weeks before
Weekly output
+50
%
Same part family and machining time · ratio 81 ÷ 54
Weekly output
+50
%
Same part family and machining time · ratio 81 ÷ 54
Load / unload time
75
→
38
s
Per part · manual vs. robot
Load / unload time
75
→
38
s
Per part · manual vs. robot
Unattended autonomy
5.6
h
140 blanks ÷ 2 lathes × 288 s cycle
Unattended autonomy
5.6
h
140 blanks ÷ 2 lathes × 288 s cycle
02
Engineering record
Challenge, approach and architecture
02
Engineering record
Challenge, approach and architecture
Challenge
Context. Two CNC lathes machining steel hydraulic fittings, 4–12 kg blanks, in batches of 200 to 2,000.
Existing process. One operator loaded both machines on two shifts. Machining time was 250 s per part, but loading took 75 s and the second machine often waited while the first was loaded, measured, or the operator was elsewhere. Neither machine ran at night.
Constraints.
Parts up to 12 kg, oily, with sharp edges.
Batch changes two to three times per week.
Machine builder approval for door, chuck and coolant interfaces.
Challenge
Context. Two CNC lathes machining steel hydraulic fittings, 4–12 kg blanks, in batches of 200 to 2,000.
Existing process. One operator loaded both machines on two shifts. Machining time was 250 s per part, but loading took 75 s and the second machine often waited while the first was loaded, measured, or the operator was elsewhere. Neither machine ran at night.
Constraints.
Parts up to 12 kg, oily, with sharp edges.
Batch changes two to three times per week.
Machine builder approval for door, chuck and coolant interfaces.
Engineering approach
One robot on a fixed base between the two lathes, a drawer buffer for blanks and finished parts, and an in-cell gauge so the cell stops if a diameter drifts toward its limit.
Scope. Cell layout and reach study; FANUC robot, 25 kg payload, 1,800 mm reach; dual grippers with quick-change jaws per part family; 7-drawer buffer with 20 positions per drawer; gauge station; safety fencing with an operator loading window; cell PLC and HMI for batch changeover.
Engineering approach
One robot on a fixed base between the two lathes, a drawer buffer for blanks and finished parts, and an in-cell gauge so the cell stops if a diameter drifts toward its limit.
Scope. Cell layout and reach study; FANUC robot, 25 kg payload, 1,800 mm reach; dual grippers with quick-change jaws per part family; 7-drawer buffer with 20 positions per drawer; gauge station; safety fencing with an operator loading window; cell PLC and HMI for batch changeover.
System architecture
Robot: 25 kg payload, 1,800 mm reach, dual gripper (raw / finished part).
Buffer: 7 drawers × 20 positions = 140 blanks.
Machine interface: door, chuck and cycle-start signals via the CNC builder's automation interface.
Gauging: in-cell diameter gauge, results logged per part; cell stops on trend toward limit.
Safety: fenced cell, safety laser scanner at the drawer loading window.
System architecture
Robot: 25 kg payload, 1,800 mm reach, dual gripper (raw / finished part).
Buffer: 7 drawers × 20 positions = 140 blanks.
Machine interface: door, chuck and cycle-start signals via the CNC builder's automation interface.
Gauging: in-cell diameter gauge, results logged per part; cell stops on trend toward limit.
Safety: fenced cell, safety laser scanner at the drawer loading window.
Deployment & commissioning
Each lathe was offline for two days during installation, one after the other. Gripper jaws for five part variants were tested at FAT; three more were added during the first month.
Open item at SAT: batch changeover averaged 26 minutes against a 20-minute target. Jaw changes are within time; drawer re-teaching is not. A drawer template per part family is being added.
Deployment & commissioning
Each lathe was offline for two days during installation, one after the other. Gripper jaws for five part variants were tested at FAT; three more were added during the first month.
Open item at SAT: batch changeover averaged 26 minutes against a 20-minute target. Jaw changes are within time; drawer re-teaching is not. A drawer template per part family is being added.
- BUFDrawer buffer140 blanks
- ROBLoadDual gripper
- CNCMachine250 s per part
- GAUGEMeasureDiameter per part
- OUTUnloadOK / NOK drawer
03
Specification & results
Specification, acceptance and results
03
Specification & results
Specification, acceptance and results
Robot payload
Part 12 kg + dual gripper
25 kg
Robot payload
Part 12 kg + dual gripper
25 kg
Reach
1,800 mm
Reach
1,800 mm
Buffer
Drawer system
7 × 20 = 140 blanks
Buffer
Drawer system
7 × 20 = 140 blanks
Machining time
Per part, unchanged
250 s
Machining time
Per part, unchanged
250 s
Part weight
Steel hydraulic fittings
4–12 kg
Part weight
Steel hydraulic fittings
4–12 kg
Parameter
Specified
Measured
Result
Load / unload time
≤ 45 s
38 s
Pass
Load / unload time
Specified
≤ 45 s
Measured
38 s
Result
Pass
Gauge repeatability
≤ 4 µm
2.6 µm
Pass
Gauge repeatability
Specified
≤ 4 µm
Measured
2.6 µm
Result
Pass
Unattended run
≥ 5 h
5.6 h
Pass
Unattended run
Specified
≥ 5 h
Measured
5.6 h
Result
Pass
Batch changeover
≤ 20 min
26 min
Open item
Batch changeover
Specified
≤ 20 min
Measured
26 min
Result
Open item
Results
Measure | Before | After |
|---|---|---|
Machines per operator | 2, constantly attended | 2, attended for loading and changeover only |
Night shift | Not run | 5.6 h unattended |
Load / unload | 75 s | 38 s |
Spindle utilisation | 54 % | 81 % |
The cycle per part is 288 s (250 s machining + 38 s load/unload). With 70 blanks per lathe, the cell runs 5.6 h without an operator.
Results
Measure | Before | After |
|---|---|---|
Machines per operator | 2, constantly attended | 2, attended for loading and changeover only |
Night shift | Not run | 5.6 h unattended |
Load / unload | 75 s | 38 s |
Spindle utilisation | 54 % | 81 % |
The cycle per part is 288 s (250 s machining + 38 s load/unload). With 70 blanks per lathe, the cell runs 5.6 h without an operator.
04
Drawings
Layout and detail drawings
Original technical drawings prepared for this record. Illustrative, not to scale.
04
Drawings
Layout and detail drawings
Original technical drawings prepared for this record. Illustrative, not to scale.
FIG. 1 · Machine-tending cell, plan view
FIG. 2 · Buffer autonomy: 70 blanks × 288 s = 5.6 h
The machines now run at night, and in the morning there is a drawer of measured parts instead of an idle shop.
Production Manager
Client · precision machining (anonymized)
PRJ-0264
05
Related
Solutions, platforms and resources
05
Related
Solutions, platforms and resources
A
Related solutions
B
Technology stack
C
Related resource
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