Renishaw plc : Precision manufacturer relies on Renishaw for the production of critical components

16 January 2012

Since adopting the machine tool probes, Associated Tools have benefited from an elimination of component rejections,a 66% reduction in tooling set up times.

The demand for the production of defence components is growing by the day in India,by their very nature, precision manufacture of these components is critical. Mr H J Bishnu, now Director of Associated Tools, took on the responsibility for the manufacturing unit in 2005filled the company's workshop with the very latest manufacturing technology, including LMW, BFWHurco CNC machine tools - all equipped with a variety of Renishaw .

Investing only in machines was not enough

However, when he first took charge, there were various issues surrounding the production techniques. Mr Bishnu recalls, "after investing so much in CNC machines, we were still facing problems with slow machining cycle times, setup idle times, inconsistencies in qualityoperator errors".

Initially in 2005, the process for loading components required manual indexinga manual dialling system with nine indexing positions. Each manual indexing process took around 45 minutes. This, followed by a further 30 minutes while the machine checked  the position, made the set up a slowinefficient process. In addition, the result of manual indexingoperator errors means that the inconsistency in quality was 5%the rejection rate 1.5%.

The tool setting process was also manual, which again contributed to time delays each time a new tool was set.

Before long, Mr Bishnu, a BTech graduate from the Halida Institute of Technology, realised that investment in CNC machine technology alone was not enough. He had visited SECO, Pune,had seen first hand the benefits of Renishaw's touch triggertool setting probes,decided they would have a great impact on his own machining process.

Dramatic results

Introduction of a CNC 4th axisOMP60 makes indexing automatic. For every indexing position, the reference point is set automatically, meaning that the component setting time is reduced to 20 minutesthe rate of scrap is reduced to almost zero percent.

The cable-free OTS optical tool settingbroken tool detection probe also brought about successful process improvements; the tool setting time was dramatically reducedalso benefited from increased accuracy. Even the tool life was optimised.

Associated Tools - well placed to compete for high accuracy work

 With two decades of experience in manufacturing valves, a special unit for manufacturing products for the defence industrythe increased accuracydecreased set up times resulting from Renishaw probing techniques, Associated Tools is now on track for growth. With the focus on manufacturingsupplying components to factories in Kolkatta, IshapurThirchi, Associated Tools aims to double or triple its defence unit turnover.

With rapid process development, stablepredictable processesautomated machines, Associated Tools is well placed to compete for high accuracy work.

Outstanding efficiency

Associated Tools has proven how the correct integration of Renishaw's touch trigger probesbroken tool detection systems, in combination with the innovative software required, can result in a highly efficient system for the manufacture of precision components for the defence industry.

As Mr Bishnu concludes: "Since we started using Renishaw probessoftware, we have been able to consistently manufacture critical components for the defence industry. There has been a reduction of 66% in set up timewe have stopped talking about component rejectionsmanual errors, as these have been eliminated completely."