High-precision processing around the clock

In a recent interview, Peter Ronge, the Manufacturing Director of Peer Inc., shared insights into a groundbreaking high-precision machining project that has transformed their production process. The project, which began five years ago, is now fully automated, with three work units producing between 750,000 and 1 million spare parts annually. These units operate seven days a week, 24 hours a day, requiring only nine operators to manage. The precision achieved is remarkable—tolerances are maintained within 10μ to 15μ, with 100% inspection ensured throughout. Ronge emphasized that the success of this initiative stemmed from forming strategic partnerships with key suppliers like Mori Seiki, Fanuc Robotics, and Mitutoyo American Corp. Instead of purchasing all equipment at once, Peer worked closely with these partners, collaborating on the development of the first unit before proceeding with subsequent orders. This collaborative approach fostered trust and ensured that each step was executed with precision and reliability. When problems arose during the project’s development, Ronge took a team-oriented approach. He encouraged open communication and focused on problem-solving rather than assigning blame. “We talk to experts as equals,” he said. “Instead of demanding ‘this must be done,’ we discuss what needs to be done and how we can achieve it together.” This mindset helped bring in the right expertise and led to the successful completion of the first work cell after two years of dedicated effort. The work cell is designed for flexibility, capable of machining various types of plastics and even combining machining with component assembly. While the first unit faced numerous challenges, the second and third units were completed more efficiently, with each subsequent unit taking less time than drafting a bill. Peer is now looking to expand further, aiming to add a fourth and possibly fifth unit by the end of the year. All external support services are located within an hour of Peer, ensuring quick response times in case of emergencies. The company’s IT department also enables remote access for external technicians, allowing them to monitor and control the work cells via network cameras and communication lines. If a machine goes offline, the automation team can remotely access the controller to make necessary adjustments. Ronge described the results as a pleasant surprise. “If not for everyone’s full commitment, we wouldn’t have achieved this,” he said. Each work cell spans 30 feet wide and 10 feet long, featuring two machining areas and a component assembly zone. Each area includes a Mori Seiki vertical machining center, a Fanuc robot, a compressed air blast system, and conveyor belts for input and output. The assembly area incorporates a bushing press-in system, a distribution system, and a Fanuc transfer robot equipped with a visualization system. The process begins when an operator places castings on a loading table. A robotic arm then picks up the casting and mounts it on one of eight fixture tables in the machining center. After processing, the robot cleans the part, transfers it to the assembly area, and installs it into the press-in system. The CMM (Coordinate Measuring Machine) then measures the part’s dimensions, recording data in the MeasureLink database and displaying results in color-coded categories—green for pass, yellow for caution, and red for failure. Using the CMM as a real-time process control tool offers significant benefits. It allows 100% inspection, reduces costs, and enables continuous operation. If a part is misaligned or contaminated, the CMM automatically flags it as defective. More importantly, it helps Peer take full advantage of customer tolerances without needing excessively high CPK values, avoiding costly processes like grinding. While Peer initially used Ovation Engineering’s EZ-Comp controller for closed-loop adjustments, they encountered challenges due to conflicting priorities between the robots and the automatic adjustment system. To address this, they opted for manual control, which proved effective with minimal adjustments required per shift. Ronge noted that the system is now stable enough to run unattended, maintaining tight tolerances of 10μ. The secret to this success lies in the material. Peer developed a specialized aluminum alloy with a local casting factory, ensuring consistent quality and stability. They also use high-quality diamond tools from trusted suppliers, which have been optimized for performance. Over time, these partnerships have led to new tooling technologies, such as advanced coatings, enabling faster and more efficient machining. Looking ahead, Peer remains cautious about adopting new technologies but believes that their current system is already highly efficient. With two years of R&D behind them, they’ve achieved high-quality output, high productivity, and low labor costs. Ronge added that if they need to increase productivity, they would prefer to replicate existing work units rather than develop new ones. The current setup is flexible enough to handle both existing and future products. Through collaboration with external experts, Peer has reached its goal, and now it’s time to reap the rewards.

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