Machine Tool Automation in Times of Labor Shortage: A Case Study

Manpower Reduction to Overcome Labor Shortages

With the decline in labor force due to the declining birthrate and aging population only expected to accelerate in the future, manpower reduction on production lines and in factories is an inevitable countermeasure.

What Does “Manpower Reduction” Mean?

Manpower reduction means making it so that the same manufacturing process and work steps can be performed with fewer workers.

In addition to eliminating labor shortages, manpower reduction also reduces labor costs and improves productivity. It may also help to advance the work style reforms demanded in recent years, and help to solve the issue of how to pass on technology and skills.

In terms of manpower reduction, consider automation through deployment of robot technology and equipment, especially for inefficient work, burdensome work, and work that does not require human labor.

Machine Tool Automation Explained

Machine tool automation refers to pairing machine tools with robots or similar to have the machine perform a machining process, in part or in whole.

Against the backdrop of an aging workforce and labor shortages, the manufacturing industry is also pushing to automate operations with aims to improve productivity. With CNC machine tools such as machining centers and NC lathes, machining is already automated with computer programs and automatic tool changer (ATC) systems.

Four Benefits of Automation

Machine tool automation offers four main benefits:

Manpower Reduction (Productivity Improvement)

With machine tool automation, the machines can operate around the clock with less manpower. By simple calculations assuming an 8-hour human workday, automated machine tools can perform the work of three workers.

Improved Quality/Stability

In manual work, human error is unavoidable. Depending on the skill level and physical condition of the operator, mistakes may occur more often. In addition, it may result in losses from damage to objects and work machinery or operator injuries. In contrast, robots eliminate any irregularities in quality and delays in work speed from fatigue.

Automation of machine tools also has the advantage of reducing the risk of accidents such as errors, breakage, and injuries while maintaining consistent quality.

Reduced Labor Costs

Machine tool automation is also effective in reducing costs. Reducing the number of operators and working hours engaged in machining work will reduce labor costs.

By automating machining operations that required many employees, labor costs can be reduced while increasing productivity for increased profit margins.

Eliminating Labor Shortages

As already mentioned, unlike humans, robots have the advantage of being able to operate 24-7. If machining can be automated, the sizable human resources freed up can be put to work on different tasks. In the past, labor shortages meant that more workers would have to be hired. By automating machine tools to reduce the number of human resources required for machining operations, those human resources can be reallocated to other short-staffed tasks.

Machine Tool Automation With Industrial Robots

How exactly are machine tools automated? Here are the main robots used in machine tool automation.

Vertical Articulated Robots

Vertical articulated robots are industrial robots shaped like human arms. Increasing the number of axes in the arm will increase the range of motion and enable various movements. A 7-axis robot is capable of movement similar to that of a human arm.

SCARA Robots (Horizontal Articulated Robots)

Sometimes called horizontal articulated robots, SCARA robots are mainly used for assembly and picking up parts. With their high-speed horizontal movement and high rigidity, these robots are capable of press-fitting parts.

Collaborative Robots

Collaborative robots are robots that work together with people at manufacturing sites. These robots are mainly used as operator support in operations such as assembly and conveyance, and they have the advantage of space saving. In some cases, collaborative robots are also used to measure workpieces after machining and to identify defective products. With NC machine tools, these robots are used for loading/unloading workpieces and changing tools.

Process-Specific Automation

There are various types and methods of machine tool automation. This section will explain automation of each process, such as for workpiece conveyance, loading and unloading, and on-machine measurement.

Workpiece Conveyance

The devices below are capable of automating pallet changes, workpiece changes and loading/unloading, and enable machine tool automation.

The Auto Pallet Changer (APC) is a device that automatically changes pallets in interchangeable table units and is mainly used in horizontal machining centers. Shuttle APCs change pallets by sliding them horizontally to the left or right. Turning APCs swivel to change two pallets.

The Auto Work Changer (AWC) is a system for automatically changing workpieces to be machined. In place of the worker, AWCs change the workpiece in the machining center between processes.

An auto loader, or gantry loader, is a device that automatically loads and unloads workpieces. Auto loaders are mostly installed atop the machine tool to convey workpieces at high speed.

On-Machine Measurement of Machining Workpieces

NC machine tools also have touch sensors to measure the dimensions of the machining workpiece. With a device called a touch probe, a sensor mounted on the spindle of the machining center or other tool is put in contact with the workpiece or jig to measure its dimensions accurately.

Measuring the workpiece dimensions after machining makes machining to high accuracy possible. A touch probe enables the measurement of the machining workpieces that required the operator to be automated.

Process Integration With Multi-Tasking Machines

Manufacturing can be automated even further by using a multi-tasking machine, which can automate various processes. The multi-tasking machine is a machine tool that integrates multiple processes that traditionally would have required multiple machine tools.

Multi-tasking machines also come with an automatic tool change feature, allowing the operator to perform a number of machining operations such as milling, turning, and grinding without changeover of the workpiece.

When each of these operations are performed on different machine tools, each of the machine tools would take up space and require an operator. Thus, using a multi-tasking machine not only automates processes, but also saves machine space and manpower.

Automation Examples

Lastly, here are a couple case studies of machine tool automation.

Mitutoyo Corporation (Utsunomiya Measuring Instrument Plant)

Looking to stabilize their quality and improve productivity, Mitutoyo Corporation deployed a SPEEDIO R450X1N equipped with a pallet changer and a robot arm for loading and unloading workpieces. Processes that once took three machines to accomplish were integrated into a single machine.

On top of that, productivity was also increased. In terms of quality stability, they report that the variation between product numbers that occurred when machining with three machines has been reduced with the integration to one machine, and that workpieces can be passed smoothly into subsequent processes. This has also reduced the burden on floor employees and improved logistics.

They also placed great importance on environmental efficiency in their selection. With its energy saving design, they expect the SPEEDIO R450X1N to help to shrink their environmental impact.

Customer Success Story Link
Mitutoyo Corporation: "Production That Used Three Machines Can Now Be Done by One"

Tachi Seisakusho MFG Co., Ltd.

Having worked on manpower reduction and unmanned operations for some time already, Tachi Seisakusho MFG Co., Ltd. deployed a SPEEDIO M200X3 equipped with the BV7-870A loading system to automate their nighttime operations.

To alleviate their concerns, various test cuts were performed when the system was introduced to confirm system accuracy. In addition to achieving their goal of manpower reduction for nighttime operations, it also shortened machining time, leading to cost reductions.

Customer Success Story Link
Tachi Seisakusho MFG Co., Ltd.: "Using a Loading System for Automation and Manpower Reduction"

Labor Shortage Measures and Cost Reductions Through Automation

Automating work that required human resources can reduce workforce, reduce labor costs, and improve productivity.

Companies that are considering machine tool automation will need to identify which operations can be automated, what kind of equipment can do that work, and calculate how much will be required for the capital investment. If your company is considering its first automation and has concerns, consider consulting with a machine tool manufacturer.