HORIZONTAL MACHINING & ROBOTIC WELDING IN CELL CONFIGURATION

The cell system uses a Toyoda FA800 horizontal machining center and two 6-axis ABB robotic welding units to address current production constraints.

D&S Manufacturing (Black River Falls, WI) recently invested in a cell system that uses a Toyoda FA800 horizontal machining center and two 6-axis ABB robotic welding units. According to Rob Bucek, the production control manager, the robust 61,100 lb FA800 was selected by a team of employees that included machinists and welding cell operators.  “When evaluating a variety of equipment manufacturers, our objective was to determine where technology had taken the machine tool industry. The group quickly focused on the FA800, which is used by large OEMs, features an 800 mm pallet and provides the increased capacity necessary to accommodate higher production runs.”

Michael Dougherty, the president of D&S, explained that the company is experiencing significant demand in the horizontal machining area and the installation of the FA800 in advance of the robotic welding systems has enabled D&S to address current production constraints. Joe Lane, the continuous improvement manager, commented that the capacity and size envelope of the existing ABB robot welders are an ideal match to the shop’s current manufacturing requirements. For this reason, D&S is purchasing two of these same units and incorporating them within the new cell configuration.

The two new robotic welding units will flank the new horizontal machining center and enable the shop to efficiently manufacture two unrelated components at the same time, dramatically increasing productivity rates. Lane concluded, “The production hours logged for our existing cell system have significantly surpassed our expectations.  As a result, both cell systems will be actively utilized to ensure the D&S team continues to meet the delivery commitments we have made to our customers.”

For more than 40 years, ISO 9001:2008-certified D&S Manufacturing has served as a custom manufacturer of exceptional quality large scale components, assemblies and complete weldments for a broad cross section of well-respected corporations that include Caterpillar, Oshkosh Corporation, Parkson, The Trane Company and CNH. The company’s extensive capabilities include technologically superior machining, laser, high definition plasma and oxy-fuel cutting, as well as manual and robotic welding.

These resources are complemented by diverse value-added services ranging from liquid spray painting and shot blasting to assembly and testing.  A dedicated and highly skilled workforce lives a commitment to superior project management, exceptional quality, accountability, teamwork and continuous improvement.

www.dsmfg.com