Quick Response Manufacturing unveiled by Mini Gears at MACH 2010

With a global reputation for supplying medium- to high-volume precision engineering components, Mini Gears has a large 35,000 ft² production facility in Stockport. From here the company has committed three Mazak Integrex multi function machine tools to support its new QRM division. Across the shop floor the work load is prioritised by the company's EFACS manufacturing system. All components destined for the QRM division are programmed offline and the NC code is transferred to the machine's Mazatrol controller via a DNC link, or with a secure flash drive. Mini Gears' engineers have carried out extensive Pareto analysis and tool rationalisation activities and, as a result, all three Integrex machine, two 300-4st and a 200-4s, are loaded with 24 common tools, as well as, Renishaw probing. Any job-specific milling, turning, drilling or process specific tools required can simply be loaded into the remaining tooling locations. Using this well organised procedure the company can typically start cutting metal in just 30 minutes. Manufacturing director, Peter Durkin says: "The inherent quality of the machines, equipped with the parts probing, allows us to work to tight tolerances, down to +/- 0.0063 mm and, from proven experience, we know that one-hit machining can significantly reduce lead times and provide a 20 per cent cost saving, on average." Although the new division has been established to provide an expedited service, company chairman, Paul Darwent is quick to point out that it is not a rapid prototyping service. "The QRM division is ideal for batches of between 5 and 50, and the more complex the finished component, the more beneficial the service will be to the customer. It is ideal for companies operating on a minimal stock level that want a secure supply, or for businesses that have been let down at the last minute by existing suppliers."