High-precision processing around the clock

Peter Ronge, the Manufacturing Director of Peer Inc., shared insights about a high-precision machining and parts packaging project that began five years ago. The initiative has largely eliminated manual operations, with three work units now producing 750,000 to 1,000,000 spare parts annually. These units operate seven days a week, 24 hours a day, with only nine operators required. The system maintains tight tolerances between 10μ and 15μ, with 100% inspection of all components. According to Ronge, the success of this project was driven by forming strategic partnerships with key suppliers like Mori Seiki Co. Ltd., Fanuc Robotics Inc., and Mitutoyo American Corp. Instead of purchasing all equipment upfront, Peer collaborated closely with these partners, working together to ensure the first unit operated successfully before proceeding with additional orders. This approach fostered trust and long-term collaboration. Ronge emphasized that his management style is based on equality and teamwork. When issues arise, he focuses on problem-solving rather than assigning blame. “We don’t say ‘This must be done’ or threaten to cancel payments if something isn’t delivered,” he said. “We speak with experts as equals.” This collaborative culture helped bring the first functional work cell to life after two years of effort. The work cell is designed for specific machining applications but offers flexibility to handle various types of plastics, including combined machining and assembly processes. While the first unit faced many challenges, subsequent units were easier to produce, with each taking less time than drafting a bill. Peer aims to expand to a fourth and possibly fifth unit by the end of the year, confident that the process will continue smoothly. All external support services are located within an hour of Peer’s facility, 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 cell via network cameras and communication lines. If the system goes offline, automation specialists can remotely access the controller for tuning. Ronge described the outcome as a pleasant surprise, crediting the team’s full commitment. “If we hadn’t all worked so hard, we wouldn’t have achieved this,” he said. Each work cell measures 30 feet wide and 10 feet long (9.1 meters by 3.1 meters) and includes two machining areas and one component assembly area. Each machining area features a Mori Seiki vertical machining center, a Fanuc robot, a compressed air blast system, and two small conveyor belts. The assembly area includes a bushing press-in system, a distribution system, and a Fanuc transfer robot equipped with a visualization system. The work cell operates as follows: an operator places castings on a loading table, and a robot picks up a part and mounts it on one of eight fixture tables. After machining, the robot cleans the part, moves it to the assembly area, and installs it into the press-in system. A split sleeve is placed on a rotating table, scanned by the robot, and then inserted into the casting. The final product is returned to the machining area for deburring and inspected using a Coordinate Measuring Machine (CMM). Results are recorded in a database and displayed in color code—green for pass, yellow for caution, and red for failure. Using CMM as a real-time process control tool offers significant advantages. It allows 100% inspection, reduces costs, and ensures consistent quality. If a part is misaligned or contaminated, the CMM automatically flags it. More importantly, it enables Peer to take full advantage of customer tolerances without requiring extremely high CPK values, which would otherwise necessitate costly processes like grinding. Peer uses Ovation Engineering’s EZ-Comp controller to adjust G-code in the machining center based on CMM data. However, integrating this system with robots posed challenges, as their priorities sometimes conflicted with the automatic adjustment system. Ronge noted that while the system works, it’s not yet fully optimized, and the team is exploring better closed-loop solutions. Maintaining precision under unattended conditions is possible thanks to a specially developed aluminum alloy with stable quality, provided by a local casting partner. High-quality diamond tools from trusted suppliers also contribute to consistent performance. Peer continues to explore new tooling technologies, such as coatings, to further improve efficiency and reduce cycle times. Despite ongoing advancements, Peer remains cautious about adopting new technologies that could disrupt its current workflow. The company prefers to replicate successful, mature work cells rather than redeveloping them. Ronge believes that the existing configuration is flexible enough to handle both current and future products. Through close collaboration with external experts, Peer has achieved high-quality production, increased productivity, and reduced labor costs. Now, the company is reaping the benefits of its long-term investment in innovation and partnership.

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