General description innovation evolution

Transcription

1 General description innovation evolution WE BELIEVE IN INNOVATION Innovation: evolution of a well-defined and shared strategic context through knowledge, creativity, research, experimentation and action by change and improvement-oriented people. OMS has the ambition of talking about and doing innovation (since we have innovated in the past and plan to innovate in the future). Since 1990, O.M.S. has been working to manufacture high precision mechanical parts based on customer design, in the aeronautical, aerospace, vacuum and hi-vacuum sectors, with continuous growth in the racing sector, particularly for the F1 championships and Motogp and Superbike championships. Our company can rely on forty years of experience in the aerospace sector (the business was started by Mr Saladino back in 1971) and a consolidated position on the national and foreign markets. Our company policy promotes a continuous research of new technologies that can further improve the quality of our products and our processes in order to meet the customers needs. Continuous interaction with the customer to offer the technical support required to identify alternative solutions that can improve the quality/price ratio. Continuous research in order to obtain maximum economic efficiency. Continuous professional growth and the use of human resources through internal and external training, promoting a positive, efficient work environment. We started to use various stainless steels (AISI 303, AISI 304, AISI 316, AISI 416L), and we have gained a thorough experience on all types of aluminium alloys (avional, ergal, enticorodal, etc.). The use of material coming from leading suppliers in the market, reliable in both delivery and quality, combined by chemical, physical and conformity analysis, allows us to maintain high standards.

2 General description innovation evolution OMS has made major investments in innovation and new technologies in the last few years: YEAR K value 30% Global turnover YEAR K value 27% Global turnover YEAR K value 23% Global turnover Our milestones are explained by few words: Done in one Process Cp-CPk management using OMSQA Strategic supplier partnership Human capital High tech production workflow MES for handling production workflow Improvement of economic efficiency Oms first obtained UNI EN ISO 9001/ 2008 back in February 1998 Our best references are: Agilent Technologies Sorin s.p.a. Spea s.p.a. Faiveley Transport Turin Politecnic

3 Oms main resources Machinery resources Mazak Integrex i200 Multitasking machine con Robot Gantry GL100 Two-Spindle Multitasking Mazak Integrex i200 machine, on which a gantry loader with sixteen pallets was installed to work in an automatic mode; it is equipped with fifth generation multi-tasking Mazak technology; it is characterized by a large work area and high precision performance, with an ergonomic design. The MAZAK INTEGREX i200 machine can complete the entire process - from raw material to finished products - in a single placement machine, relying on a large integrated tool inventory that serves 110 workstations. The spindle of high-speed milling, of advanced design, can take up to 240 -degree angles and the two electro-spindles contribute to an unparalleled machining flexibility. In addition, the large X-axis ( 615mm to 125mm excursion over the zero spindle) and an improved Y-axis ( 250mm stroke) are designed to further facilitate the use of the machine. The B-axis indexing and positioning of the cutter head allows increments of due to the coupling between the shaft and gear camshaft bearings and linear scales in standard. The Mazak Integrex i- 200 machine was equipped with a Renishaw probe for automatic measurements during the machining process, which makes it possible to run finished products in the machine, with a tolerance of mm. The combination of the precision offered by the machine, the gantry loader and the Renishaw probe allow us to move from the rough bar to the finished product, milled in three positions, in a totally automated single cycle.

4 Oms main resources Machinery resources Mazak Integrex 200 iv s ST con Robot Gantry GL100 A 9 axis machine controlled by CNC, with workpiece loading and unloading, automatic laser measurement system (marposs), self-correction of parameters based on machine measurements, high pressure refrigerating system (75 bar) filtered and thermo-controlled, positioning system with optical lines (0.002mm precision), 82 tools available. Mazak Integrex 200 iv s A 9-axis machine with absolute position reading on optical lines - no encoder - for absolute accuracy, repeatability 0,0015 mm, refrigeration at the centre, pressure at 20 bar, housing 40 positions on the milling and turning head, and 9 positions for the lower turret (only turning), ASA 6 double mandrel, with the same line bearing head, to have 2 mandrels working with equal performance as opposed to a primary head and a recovery head.

5 Oms main resources Machinery resources Mazak Integrex 100 Multitasking machine A 7-axis machine with absolute position reading on optical lines - no encoder - for absolute accuracy, repeatability 0,0015 mm, refrigeration at the centre, pressure at 20 bars, housing 40 positions on the milling head, ASA 5 double mandrel, with the same line bearing head, to have 2 mandrels working with equal performance as opposed to a primary head and a recovery head. Mori Seiki NLX2500/700 S/Y Lathe The Mori Seiki NLX2500 lathe makes it possible to reduce the Lead Time, thanks to the one clamping operation, its 2 work heads, double tools system, and automatic workpiece unloading. This working method takes the name of Done In One Process; this machine features standard and optional equipment that allows a measurement uncertainty within ± in the production setting. Technical details Turning max. lenght (mm) 728 Turning max. diam. (mm) 460 Bar passage (mm) 80 Number of tools 12 Axis Stroke X/Z (mm) 260/795

6 Oms main resources Machinery resources MT Module for Mastercam X7 Mastercam Mill-Turn eliminates unnecessary steps and simplifies the programming of multi-stream multi-tasking machines. Setting of Work: Choose the initial machine environment. Mastercam uses these settings to automate the transfer of the workpiece, creating work plans, the definition of the raw and the management of workflows. Tools and processes: Mastercam Mill -Turn combines the power of the working strategies of milling and turning to get the best of their multi- turret machine; greatly simplifies the combination and synchronization of the machine axes, the creation and choice of tools and processes appropriate to the task at hand. The result is simple programming, fast, reliable and optimized. Automatic workpiece transfer: The definition of the machine pre- set, the management of the transfer of crude oil becomes simple and automatic. Synchronization Manager: The synchronizations management system provides a simple and at the same time very powerful interface to treat quickly and intuitively different workflows that the multitasking machine must perform. Machine Simulation: It simulates synchronized operations and optimized as if you were on the machine to get an accurate preview of the final work. Process Workflow: It generates machine codes suitable and optimized for your machine. 5 axes CNC and Continuous milling work centers The CNC milling department consists of Mitsubishi work centres, 3 of which are for high-speed machining (mandrel line with turns/min), reading on optical lines, temperature compensation, MAZAK Integrex GT, MV 5000 Mori Seiki The advantages and excellent features are: Complete machining of complex pieces with only one positioning 340 deg. rotation of the rotary table, free table with a single anchorage point Position transducers with laser optical line, with complete linear measurement without rotary encoder Power transmission to the rotary axes without gears Total reduction of thermal expansion Accelerations carried out on the machine centre of gravity, vibration free System for measuring piece dimensions MARPOS

7 Oms main resources Machinery resources MITSUBISHI MVC5-L 4-AXIS C.N.C. WITH FANUC RISCK CARD (HI-SPEED) Mandrel line with turns/min Fanuc look-head software to for high-speed interpolation control Data server - 2Gb memory Reading on optical lines - precision ±0,002mm Working stroke: axis X-1000 mm, axis Y-550mm, axis Z-500 mm Table diameter 4/5 axes Nikken: 180 mm MITSUBISHI MVC5-L 4-AXIS C.N.C. WITH FANUC RISCK CARD (HI-SPEED) Mandrel line with turns/min Fanuc look-head software to for high-speed interpolation control Data server - 2Gb memory Reading on optical lines - precision ±0,002mm Working stroke: axis X-900 mm, axis Y-550mm, axis Z-500 mm Table diameter 4/5 axes Nikken: 180 mm MiTSUBISHI MVC5-L C.N.C. WITH FANUC RISCK CARD (HI-SPEED) Mandrel line with turns/min Fanuc look-head software to for high-speed interpolation control Data server - 2Gb memory Reading on optical lines - precision ±0,002mm Working stroke: axis X-750 mm, axis Y-550mm, axis Z-500 mm Table diameter 4/5 axes Nikken: 180 mm VERTICAL WORK CENTRE WITH 4 AXES CONTROLLED BY MITSUBISHI 5VC C.N.C. Mandrel line with turns/min Fanuc look-head software to for high-speed interpolation control Data server - 2Gb memory Reading on optical lines - precision ±0,002mm Working stroke: axis X-900 mm, axis Y-550mm, axis Z-500 mm Table diameter 4/5 axes Nikken: 180 mm

8 Oms main resources Machinery resources MAZAK Integrex GT Designed and built according our own specifications it is a turning and milling centre at 9-axis controlled by 2 CNC, 80 tools, optical encoders, laser measuring system in contact, cooling to 70 bars and temperature controlled, robot loading and unloading of workpieces. This plant is used for the vacuum production (70%); we have industrialized the manufacturing process for the rotors of the "Leonardo" and bodies of the "Leonardo" in a single socket machine while providing measurement and automatic correction of parameters. All this translates into economic efficiency of our products and guarantees manufacturing excellence. Following analysis of production processes, we assessed production volumes, cost efficiency and the various production lots: implementing the quantities produced and the number of units assigned to a single lot, we got an economic efficiency in the production of rotors turbo of approximately 8%, spring spacer and bottom flanges of approximately 12% (see Oms economic offer efficiency no. 98 and 99 of ).

9 Oms main resources Machinery resources Dea Tigo Three-dimensional measuring machine A "touch" of innovation to the workshop measurement TIGO SF Measuring Machine is versatile and high performing, ideal for workshop use and requires no air supply. Its robust and compact design ensures extremely precise measurements while its innovative operating principle simplifies the dimensional inspection of any workpiece, making the world of metrology accessible to all. Designed to operate in harsh environments, TIGO SF is fully protected by guards and bellows and represents the ideal combination of strength, flexibility and innovation. Thanks to its structure cantilever, TIGO SF is fully accessible from three sides, and provides optimal access during the programming phase, both for the operations of loading and unloading. The robust and large granite top, equipped with a dense grid of threaded holes, makes it extremely easy to mount workpieces.

10 Oms main resources Machinery resources Tesa Visio Optical measuring machine Dea global advantage measuring machine No-contact optical measuring machine A 5-axis measuring machine with CMM coordinates. Mitutoyo profile projector ph-3500 Double-access projector, allows the projection and the control of profiles Altimeter hi-precision tesa accouracy: mm Altimeter Mestra 300 Trimos Sylvac Measurement system (diameters/distances/flatness/spans ) of very high precision

11 Oms workflow The production cycle is constantly submitted to verification trials, after which the product is followed and certified, from the acceptance of materials used to the construction and packing phases, and is finally put to careful testing at the end of production, thus ensuring a very high quality product and obtaining strictly monitored size limits and excellent surface finishes. Since 2000 Osm has been working to develop a workflow to reduce processing steps and interruptions, thus ensuring a smooth and fast manufacturing process and maximum precision. In a word? Creativity Anyone can invest a billion dollars in machinery, but not all can rely on our creativity and experience to solve problems. Nobody thinks it possible to produce a workpiece, especially without human control. OMS just do it with: Constant maximum precision: 20 critical quotes, 7 quotes at tolerance CP at 1.33 About customization of machinery High production rate Real time self parameter misuration and adjustment Complete Process done at mm precision On-board measurement with linear optics Customized high pressure water washing Customized filtering and chip removal How to standarize this strategic job? See in next slide with MES system

12 Supplier, Store, Quality, NC, Handheld management Handled device already are employed for all production task It is now possible to manage the acceptance of raw materials totally by handheld devices, which, through bar code reading, are automatically loaded to the warehouse and divided into identification lots. As far as quality is concerned, a dedicated procedure has been developed relating to acceptance controls. Similarly, the tooling supply is managed with the load on stock by reading the barcode of the input material. Appropriate procedures have been set up to manage orders to suppliers. After setting all the details required to complete the order, an is automatically generated and sent to the supplier. In order to improve its quality standards, OMS has decided to notify and manage Non Conformity issues during production by handheld devices. If a defect is detected in production, a Non Conformity sheet is completed at the machine, accompanying the information sheet with photos of the issue in question. Storage area of raw materials and roughing In order to improve productivity, OMS has decided to place all raw materials in an area best suited for storage, performing roughing operations on machines fit for this purpose. This results in savings in terms of money and time because high precision machines suitable for finish machining are no longer involved. Knowledgmet on miltiples stainless steels We started to use various stainless steels (AISI 303, AISI 304, AISI 316, AISI 416L and we have gained a thorough experience on all types of aluminium alloys (avional, ergal, enticorodal, etc.).

13 Cp-CPk management using OMSQA OMSQA was developed by Oms to manage CP and CPk. This software provides: Real-time data collection Network infrastructure: 2 last generation hubs (1 giga) and 30 on-line links through direct wires Automatic data formatting for Minitab Automated, mistake-free integration with Minitab Data available within 10 seconds as opposed to several minutes Customized dashboard control of workpieces after measurements Parameter querying at any time: - Manufacturing time interval - Batch - Code - Machine - Operator - Testing Three measuring machines and two trials for more than 30 measurements on a workpiece

14 MES for handling production workflow How can Done in One Process translate into a standard transferrable workflow? MES is the answer MES makes it possible to analytically codify manufacturing tasks and present them to the operator. Thanks to touch devices to show the task to be accomplished as well as to validate and read accomplished tasks, operators are interchangeable and manufacturing can be easily relocated. MES will make it possible to increase the detail level to five times as much the existing level. MES will be developed in cooperation with Turin s Politecnico, Department of Management and Production Engineering, using a software house for one year Improvement of Economic Efficiency Why do we do all that we have described above? We like it and it is our passion. Just one Example? With an agreement, focused on the increase volume of each part produced a client has obtained in 2013, a reduction in the cost of about $ 110,000 for the same supply of 2012.

15 High Tech Production Workflow Supplier and supply assessment, validation, acceptance Computerized order management Computerized production management with BOM Analysis, Laser marking, 6 Sigma Quality system Synoptic module Cp and Cpk DOE (Design of Experiments ) to confirm manufacturing feasibility of a workpiece based on specific characteristics and on a standard process Computerized delivery scheduling Human Resources Oms has adopted a team-based organization, with project leaders both at management and operations level. The General Manager Luca Saladino is responsible for innovation, supported by the founding managers of the company and by production managers, trained within the company for years. In Oms employees are recruited and trained by the company owners Operators are empowered within the company based on manufacturing strategies and quality.

16 Strategic Supplier Partnership Oms suppliers are accurately selected; a supply tracking system is in place and direct agreements are signed with major suppliers Namely: Machinery: Oms deals directly with parent companies. Direct purchasing is the result of a careful selection of configuration options. Configuration options and the use of such options are considered as an added value; this is the reason why Oms is considered as a partner tester by major manufacturers. Major suppliers include MAZAK, DMG MORI, CITIZEN and HEXAGON Tools: Oms has signed supply and partnership agreements since it designs tools manufactured by SANDVIK and NACHI. Products developed in partnership include cutters and quenching furnaces. This partnership will be further developed as part of the MES project: the most important improvement challenge in Measuring tools: Oms utilises HEXAGON tools, in close cooperation with Hexagon experts to improve performance and develop new products (ex Tigo St) and to ensure constantly updated calibration

17 Supplier, Store, Quality, NC, Handheld Management Handheld devices are already used for all production tasks Storage area of raw materials and roughing Knowledge of multiples stainless steels Direct connection to handle nocturne Software: connected with customers inventories through Alex software to check inventories on a daily basis and plan restocking with no need for direct orders

18 Certification UNI EN ISO 9001/ 2008 since February 1998 References Agilent Faiveley Transport Spea Equipment Sorin Biomedica Turin Politecnico Brembo s.p.a.

19 Oms main resources Machinery resources It is a 5-axis milling centre, with linear scales of production (accuracy ± 0,002 mm), 60 tools, measuring system and automatic correction of parameters and control over the life tool that allows us to work to the highest levels of technology. Intended 50% for the production of special pneumotronic (class brakes) and 50% for the vacuum production (pump bodies) from Tv750 to Tv1k-g. As far as the high-vacuum applications are concerned, we have revised the production process of some pump housings, reducing machine tool change (production stages) from 7 to 3 placings machine. This allowed us to reduce the cost of such details (high-vacuum pump bodies) from 8% to 14% (see cost efficiency proposal to Agilent in March 2012 to supply pump casings with Oms no ) ensuring fluidity and continuity of production of around 180/220 workpieces a month and repeatability of the production process without hesitation. 8 CNC lathes 2 axes work center for CNC turning The turning department consists of 8 CNC lathes for which precision, depending on the type, goes from 0,005 to 0,002 mm, up to 0,0005 on the Hardinge Quest 42 lathe. The CNC Axis Y turning department consists of new generation turning integrated with axis Y and motorised tools, with which, thanks to the combination of milling and turning in a single operation, we perform the most complex and precise work

20 Machinery resources Oms main resources