Multitasking Machine ROI: A Shop Investment Guide

Multitasking Machine ROI: A Shop Investment Guide

Consolidating operations for recurring parts production in a single multitasking machine can be a more attractive investment than building out a multimachine operation. So, how do you determine whether a multitasking machine delivers the right benefits for your shop’s next purchase?

First, let’s look at the basics.

What is a multitasking machine?

A multitasking machine combines turning, milling, surfacing, drilling, tapping, and hobbing in a single machining environment. Beyond additional capabilities, the business value for multitasking machines is the potential to simplify the process from raw material to finished parts.

Multitasking machining: A production approach that combines compatible machining operations that might otherwise require separate machine tools, setups, fixtures, and part transfers.

On-the-floor benefits of a multitasking machine include:

• Reduction in setup time: Parts are machined in a single cycle, which means you don’t need to perform multiple setups, change tooling or fixtures, adapt programs, or move a physical part between several different processes.
• Increased spindle utilization: Because a multitasking machine eliminates the need to move parts between machine tools, it allows for more active cutting time.
• Improved accuracy, reduced errors: The most consistent process is one that reduces setups and production steps. Multitasking machines vastly reduce the risk of human error and production downtime.
• Decreased total cost of ownership: Reducing manufacturing to a single multitasking machine will require fewer fixtures, tooling, and labor hours, as well as less money spent on routine maintenance.
• More shop floor space: Valuable shop floor space becomes open by condensing multiple machining operations into a single machine.

Where does a multitasking machine make financial sense?

A multitasking machine is most relevant for shops working on recurring part families. Current workflows include multiple machining operations with processes that create avoidable setups, transfers, handoffs, or production constraints. Jobs that are the best candidates for multitasking machines are not necessarily those making complex parts, but rather those where processes can be consolidated.

Here are a few criteria that would make your shop the perfect candidate for this machine:

• The same part moves between turning and milling operations.
• The part requires multiple setups, fixtures, or program changes before it is complete.
• Operators spend meaningful time moving, re-fixturing, or restarting parts between processes.
• A part waits for the next available machine after one operation is complete.
• The shop needs more output capacity for an existing part family.
• Current routing poses a quality risk due to repeated handling or setup changes.
• Floor space is constrained by multiple machines used to complete the same part.
• A stable part process may be suitable for compatible material-handling automation.

• The shop is evaluating RFQs that require combined turning and milling work.

   

How can fewer setups affect cost per part and output capacity?

Fewer setups can reduce the work required to complete a part because the part may need less handling, re-fixturing, and movement between machines. The financial value depends on the shop’s actual setup time, labor requirements, routing delays, tooling and fixture needs, and demand for the capacity that is released.

Questions To Consider

Process Factor: Setups

• Multitasking Workflow To Evaluate: Determine whether compatible operations can be completed with fewer setups.
• Business Question: What setup time can be removed from the process?
   

Process Factor: Part transfers

• Multitasking Workflow To Evaluate: Determine whether the part can remain in one machining environment for more of the process.
• Business Question: How much handling and queue time exists today?
   

Process Factor: Operator involvement

• Multitasking Workflow To Evaluate: Compare current touchpoints with the proposed process.
• Business Question: Which operator tasks are reduced, changed, or still required?
   

Process Factor: Fixtures and tooling

• Multitasking Workflow To Evaluate: Compare current requirements with the proposed setup.
• Business Question: What changes in fixture, tooling, and setup investment are required?
   

Process Factor: Floor space

• Multitasking Workflow To Evaluate: Assess whether process consolidation changes the production footprint.
• Business Question: Does the release of floor space create a meaningful business benefit?
   

Process Factor: Output capacity

• Multitasking Workflow To Evaluate: Model the proposed route using validated cycle and handling assumptions.
• Business Question: How many more completed parts can the process support if demand exists?

IMPORTANT: Do not count released machine time as financial value unless the shop can apply that capacity to demand, avoid another investment, or otherwise convert it into a business outcome.

How can I calculate the ROI of a multitasking machine?

Conducting a time study with an existing part can reveal the time and cost savings of a multitasking machine. Identify and select a recurring part or part family that currently requires multiple compatible operations and has enough production volume or strategic importance to make process improvement meaningful. A time study should focus on the actual workflow, not an idealized version of it.

Suggested evaluation questions:

• Does this part require both turning and milling work?
• How many setups and fixtures are required today?
• How often is the part moved between machines?
• Where does the part wait in the current route?
• Which tasks require an operator at each stage?
• Is the part a repeat job, a growing opportunity, or a process bottleneck?
• Could automation support material loading or unloading for this application?

• What quality requirements must be maintained throughout the process?

   

How can automation strengthen a multitasking investment?

Automation can increase the value of a multitasking process when the application, material flow, part handling, and operating requirements are compatible with unattended or reduced-intervention production. These solutions should be evaluated as part of the complete process.

When a part process is stable and compatible with automated material handling, a multitasking machine can be evaluated alongside bar feeders, loading and unloading systems, or robotics. The right automation approach depends on the part, the process, material flow, inspection needs, and desired operating model.

How can Okuma and a local distributor validate the opportunity?

An Okuma multitasking investment should be validated through a part-specific application review, time study, or live demonstration. Local distributors bring application-level knowledge to individual shops, while Okuma provides the machine-tool and control expertise of a single-source OEM.

A distributor-led evaluation should examine:

• The part drawing and completed part requirements
• Current routing, setups, and handling steps
• Programming strategy
• Tooling and work-holding
• Compatible multitasking operations
• Control requirements
• Automation options, if relevant
• A validated time study or live demonstration using a representative application

A complex finished part depends on machine capability, multi-axis access, programming strategy, tooling, work-holding, and control performance working together.