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Process

At DMG / Mori Seiki / Ellison Technologies we develop solutions to solve our customers most pressing challenges. We measure the value of those solutions through the eyes of the customer, and tailor solutions around their individual needs and processes. We invite you to review some of the innovative results that have been accomplished as it pertains to specific manufacturing processes.

Performance Technologies Inc.

Industry:  Aerospace, Automotive, Industrial
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing
Performance Technologies manufactures male and female rod end body blanks. Their customers include New Hampshire Ball Bearing, Kamatics, PSI, and other manufacturers supplying finished rod ends to the Aerospace, Automotive, and Industrial Markets.
Before: 

• Labor Intensive  
• Multiple Machines per part
• Poor quality due to multiple set ups

After: 

• One operator produces 10X as much  
• Operations combined on one machine

Blue Chip Engineering, Inc.

Industry:  Medical
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing
Blue Chip Engineering is a precision machining job shop supplying quality components to the medical industry. Blue chip’s capabilities include a full range of technology, from 2 axis to complete 5 axis machining, offering flexibility and quick-response capability to address their customers’ cost and delivery requirements.
Before: 

• Low machining process yields  
• Excessive Scrap
• High labor component

After: 

• 30% reduction in cycle times  
• 20% reduction of labor
• Significant reductions in scrap

Pazmac Enterprises Ltd

Industry:  Energy / Oil & Gas, Semi-conductor
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing, Continuous Flow
For more than 30 years, Pazmac Enterprises has been a job shop manufacturing components for the oil & gas industries, wood products industries and marine electronics industries. Beginning as a manufacturer of fasteners with manual machine tools, this company purchased their first CNC machine tool in 1994.
Before: 

• Multiple Setups requiring many hours 
• 25% On-time Delivery 
• Inventory carried for quick customer response
• Moderate throughput

After: 

• Setup time - reduced 75% 
• 85% On-time Delivery 
• 50% reduction in inventory
• 300% improvement

Clay Precision

Industry:  Agriculture, Semi-conductor, Trucks/Engines/Engine Blocks
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Unattended Manufacturing, Cellular Manufacturing, Continuous Flow
Clay Precision is a supplier of precision-machined piece parts and assemblies. They serve the needs of a diverse customer base with an emphasis in the semiconductor industry. Clay is recognized for their ability to machine intricate parts with complex tolerance requirements.
Before: 

• Limited floor space
• High setup times
• Poor work flow

After: 

• 10%+ increase in available floor space
• 50% setup time reduction
• Organized and standardized work areas

Clow Valve Company

Industry:  Agriculture, Industrial
Process:  High-speed Manufacturing, Multi-process Manufacturing, Multi Axis Machining, Robotic Automation, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing, Continuous Flow
The Clow Valve Company manufactures and distributes a variety of Water valves, Hydrants and Pipe, for residential housing and industrial development projects within state and local municipalities.
Before: 

• Multipleoperations and set-ups
• High labor content
• Multiple routings and heavy WIP
• High machining costs
• Numerous handling of heavy parts

After: 

• One continuous process
• Cell attended by a single operator
• Elimination of batch and queue WIP
• Lowest per-part manufacturing cost
• Valve untouched in machining cell

Von Ruden Manufacturing, Inc.

Industry:  Agriculture, Industrial
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing
The company is a leading manufacturer of mechanical power transmission and fluid power products for the machine tool, mobile construction, commercial landscape and industrial systems markets. Primary products include gearboxes, hydraulic motors/brakes, bearing blocks, rotary/driven/live tooling and customs. Designing and manufacturing solutions in Minnesota since 1946 with 60+ years of gear and bearing expertise, 30+ years of hydraulic seal and pressure expertise and in 2001 combined these technologies into an industry leading rotary tooling line for many machine tool manufacturers.
Before: 

• 525 minutes in set-up  
• Four operations, seven days in WIP 
• High scrap potential through set-up and handling  
• Eight weeks planning lead-time

After: 

• 30 minutes set-up, 95% reduction 
• One operation, one day in WIP, 85%  
• Scrap all but eliminated, 95% reduction  
• Less than three weeks, 65% reduction

Olympic Arms

Industry:  Agriculture, Industrial
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing
Olympic Arms supplies firearms to the recreational, military and law enforcement industries. They manufacture a complete line of automatic rifles and pistols from their 16,000 square foot facility staffed by 60 employees. The company is recognized for its creative product design and complete commitment to customer satisfaction. They pride themselves on the ability to rapidly bring innovative and quality products to market.

Rochester Precision Machine, Inc.

Process:  High-speed Manufacturing, Multi-process Manufacturing, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing
Rochester Precision Machine, Inc. (RPM) is a precision machining job shop serving multiple manufacturing sectors. Operating two shifts from a 12,000 square foot facility, their team of 14 employees provide product to a diverse customer base, ranging from Fortune 100 companies to small, local product manufactures. RPM is recognized for product quality, on-time deliveries and their ability to respond to customer needs.
Before: 

• Multiple process operation 
• Could not compete on complex parts 
• Interrupted process with high labor

After: 

• Machine component complete  
• Increasing market share 
• Additional throughput capacity

Muse Metal Laboratories, Inc

Industry:  Agriculture
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing
Muse Metal Laboratories is a supplier of precision-machined components to the defense contracting and geophysical industries. The company has 15 employees operating out of an 8,500 square foot climate-controlled facility. Their success stems from the ability of their skilled work force to produce highly complex components from tough and abrasive stainless steel alloys to exacting tolerances, work generally passed over by more production oriented job shops.
Before: 

• Multiple Operations  
• Multiple Setups 
• High cost at larger lot sizes

After: 

• 25% increase in throughput  
• 40% reduction in setups 
• 20% reduction in part cost

Ronlo Engineering

Industry:  Aerospace, Automotive, Medical
Process:  High-speed Manufacturing, Multi-process Manufacturing, Setup Reduction, Multi Axis Machining, Unattended Manufacturing, Swiss Machining, Horizontal Machining, Cellular Manufacturing, Continuous Flow
Ronlo Engineering supplies precision piece parts to the Aerospace, Automotive and Medical industries. Primary products include manifolds and hydraulic fittings produced from a variety of materials, such as; titanium, inkenel, and stainless steel. Family owned, Ronlo Engineering occupies a 22,000 square foot facility and employs a team of 35.
Before: 

• Labor intensive process
• Low profit parts
• 4 operations with 4 set ups
• Three week lead time

After: 

• Unmanned cell operation
• Most profitable parts
• 2 operations and 2 set ups
• 93% reduction in lead time

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