06 August 2010
Automated manufacturing facility makes early impact on MASS agreement at BAE Systems
A recently commissioned fully automated manufacturing facility for the machining of 105mm and 155mm artillery shells has made an early impact on the aims of the MASS contractual partnership between BAE Systems and the UK MoD.
MASS (Munitions Acquisition - the Supply Solution) -aims to deliver increased supplies of ammunition to front line troops by modernising and ensuring sustainability of the UK munitions industry.
Although due to be relocated to a brand new £28 million facility in Washington Co Durham, the recently installed manufacturing facility is currently operating at BAE Systems' Birtley plant which dates back to 1916. Operating alongside an existing manually operated facility, the new manufacturing cell removes operators from potentially hazardous areas, occupies a quarter of the space, requires 4 less operators per shift, has increased product quality and has increased available capacity.
The overall system comprises four progressive separate robot loaded manufacturing cells capable of independent operation, and allows maintenance and retooling to be undertaken without stopping production. The system is designed to manufacture both the 105mm and 155mm shells with quick changeover routines embodied into the manufacturing processes.
The order was awarded by Bae to Mills CNC Ltd, who took responsibility as the prime contractor for the complete project. A significant criteria was the tight delivery schedule required by Bae which was system pass off on site within 12 months, which was achieved.
Cells one to three each have two Doosan Puma 400C CNC lathes, with Cell four having a single Puma 400C. Each cell includes a FANUC Robotics R2000iB/175 robot which loads the machines and a variety of peripheral equipment required to complete the process.
Shells are progressively machined in each cell, with transfer between cells managed by outputting machined parts onto pallet conveyors designed by Ewab Engineering Group for collection by the robot in the next cell. These link conveyors also provide a minimum buffer storage to allow continuous production even when a machine is stopped for re-tooling. LEAN manufacturing processes are employed to identify waste within the system and, to ensure the system will run continuously with planned stoppages to individual machines.
On receipt of order Mills CNC contracted the system integration of equipment and communications to FANUC Robotics UK limited. Jeff Robson, MASS Transformation Engineer for BAE Systems Birtley, commented, " Machining the shells is the core process on this system so Mills, who had previously successfully developed similar automated systems within BAE Systems, was the natural selection for prime contractor. The effective operation of this system has been the result of a successful partnership between BAE Systems, Mills CNC and all the suppliers involved.
"Communications are enabled through I/O at machine level with the Fanuc Profibus interface enabling significant volumes of data to be collected for OEE (Overall Equipment Effectiveness) calculations and display of system performance through a large central monitor positioned on the shop floor".
Advanced manufacturing software has allowed BAE Systems to develop and apply strict controls throughout the machining process, re-tooling, material supply and maintenance procedures - SMS messages and E Mail prompts are activated by the system to specific Team members to ensure that the required human intervention is made when needed.
The four Fanuc R-2000iB robots each have specially engineered grippers designed by FANUC Robotics - these handle the shell either on its Outside Diameter or the fuse bore Internal Diameter. Each cell has two way powered conveyors for periodic part inspection outside the working area of the cells.
Cells three and four both have marking systems developed by
Pryor Ltd into which the cell robot positions and holds the shell
as information, defined by the process, is applied to the outside
of the shell. In addition, Cell three involves a shell weighing
operation which feeds back information to the Puma 400C control
system and results in the correct amount of material being machined
to maintain a consistent mass of each shell.
One cell includes an advanced robotic flaw detect inspection system
using Eddy current and phased array technologies supplied by NDT
Ltd into which the cell robot loads and unloads machined shells. In
another cell the robot picks and loads a Copper driving band to a
pre-machined groove which is then pressed to fit in a two press
operation designed by Orwin Ltd.
Linear rails are employed in two cells to provide the respective
robots with a greater working range to service the machines and
various ancillary equipment involved in the cell processes.
Jeff Robson continues, "Operator uptake and acceptance of the
system has been excellent - we have a saying which we stick to when
engineering any process ‘Simple's best, simple's easy and simple's
understood' - this works for us as we avoid unnecessary
complications so operators can take it over, monitor performance
and invariably improve upon it using a PDCA (Plan, Do, Check, Act)
philosophy!
"We are due to start to move to the new facility in September and this system is already effectively contributing to the efficient cost-down manufacture of munitions for the MoD."