The Power of the Multitasking Process

David Fischer:

Good morning, everyone, my name is David Fischer, Lathe Product Specialist at Okuma America, and I'm joined by Craig Mainzinger with our Applications Engineering department, and today we're going to talk about the multitasking process, and how it can help shops better compete in today's marketplace.

David Fischer:

First we will start out talking about what a multitasking machine is, and why they can have such a powerful impact on your business. Then we'll talk about the advantages of the multitasking process itself, and finally we will highlight some of Okuma's multitasking functionalities and capabilities.

David Fischer:

So the original multitasking machine, well sort of. The Swiss Army Knife is often used as an analogy for a multitasking machine. It's great in that people instantly get the idea of having all the tools I need, but I feel that it fails on two important points. First, the Swiss Army Knife has many different tools, but generally speaking you use them one at a time. They're not integrated, and integration is the key to the power of the multitasking machine. Second, although it has a lot of tools, none of them are as good as having the individual tool. Would you prefer to use a screwdriver on a Swiss Army Knife, or use an actual screwdriver? The individual tool is better, but that is not the case with today's modern multitasking machine tools.

David Fischer:

I feel that the smartphone is a better analogy. Combining all the capabilities of a camera, phone, GPS, etc, as well as various sensors, we have a more compact and more capable device than when we had all of these individual devices stuffed in our pockets, or hanging from our belts. With this integrated capability we go beyond the functionality of the individual components to being able to see where you parked your car, summon a ride, do FaceTime, etc. So the same thing has happened with machine tools, the multi-tasking machine, combining turning and milling capability at a minimum to provide even greater functionality, integrated functionality with little or no sacrifice.

David Fischer:

The multitasking process provides many advantages over the conventional process, but not every application is a multitasking application. Low mix, high volume processes are generally not ideal candidates for multitasking. However, many others are. Agile manufacturing. If ever there was a year where being agile was important, it has been this year. Being able to quickly pivot has been critical to survival, and multitasking machines make it easier than any other platform. Processes requiring mass customization. Low to medium volume production is a good rule of thumb for multitasking, but as the machines get faster, the bar gets raised. Set up reduction or elimination, particularly on repetitive production, high complexity components, and finally, processes where you want to minimize operator intervention.

David Fischer:

For example, in producing this part using a conventional process, we have five machining operations requiring various fixtures, rotary tables, and tooling. Comparing that to the multitasking process, we have a single machine and no special fixturing. The conventional process requires heavy operator intervention, the operator having to handle the part 10 times. The multitasking process requires just a single load/unload, so just two handlings. The multitasking process is always balanced, the conventional process is not. Interrupting for a hot job is a minimal disruption on a multitasking machine where it is quite often a major headache using the conventional process. And finally, the multitasking process really doesn't have any work in process, just raw material, and finished goods.

David Fischer:

Machines set up time is one key area where multitasking machines bring major improvements. On special work, they eliminate the need to have elaborate fixturing systems, rotary and tilting rotary tables, it's all built into the machine. On short to medium run jobs that are repetitive, many times the tools are in the magazine. Just change the jaws, call up the program, and you're back in production. Set up times of less than 10 minutes are possible, and the impact this has when change over time no longer matters is a serious game changer.

David Fischer:

For a typical setup, you have your lathe and machining center workholding, rotary tables, machining center tooling, and lathe tooling. With multitasking machines, we eliminate the need for most of this, simplifying the setup and the overall process. A multitasking machine is a highly tuned system. The castings, drives, motors, and control system must be balanced to provide the best performance. Okuma's one source design and build philosophy gives us total control of all aspects of the machine tool, from the casting design to our OSP control, each component is designed to complement the others.

David Fischer:

Early multitasking machines made many sacrifices to add functionality. The goal has always been to provide turning and milling capability without compromise, and with the MULTUS family of multitasking machines, this goal has been fully realized. Shown here is our MULTUS B750, which has the turning capabilities of our powerful LB45 turning center, and the milling capabilities of our highly regarded MA-600 horizontal machining center.

David Fischer:

A wide range of automatic tool changes are available so you always have the tools you need, as well as backup tooling for long run jobs or difficult to machine materials.

David Fischer:

Okuma's Collision Avoidance System, standard on the MULTUS Series, protects the machine using 3D simulation that works in manual, MDI, and auto mode, so you are always protected. Also provided is a library of workholding, tooling, and tool holder models, or create your own with the provided easy modeling software.

David Fischer:

Okuma's long boring bar option provides the ability to use long boring bars that are outside the capabilities of the ATC, and beyond the capability of traditional turret type lathes. Allowing bars of up to one and a quarter meters in length, this option is ideal for parts requiring deep ID work. This option provides the ability to change the cutting unit on the bar, so that it's easy to change between cutting operations.

David Fischer:

With the integrated functionality that multitasking machines provide, additional capabilities can be added to the machines such as hobbing, and as seen here, skiving. Performing this operation on a multitasking machine eliminates the need for an additional operation, or having to send it to an outside vendor. In addition, using the gauging capabilities of the machine, the part can be measured and the process tracked throughout the operation.

David Fischer:

Integrating the turning capabilities with the rotary B-axis permits the machining of complex turning geometries without resorting to special tools, or several different cutting tools. In this example we're able to use a single standard cutting tool to machine this face, complete with an excellent surface finish free from all blend marks.

David Fischer:

Okuma's turn cut function provides the ability to turn diameters in almost any position in any angle. In addition, the gauging function is able to measure with similar capabilities to control the process. And finally, the measurement of surface finishes is also possible.

David Fischer:

Okuma's LASER EX function is capable of doing laser hardening and laser metal deposition. Laser hardening can provide material hardening in very specific locations with very low distortion. Laser metal deposition is also available for building complex geometries and performing metal cladding.

David Fischer:

Multitasking machines minimize operator intervention by design, but Okuma's ARMROID robot loader provides fully automated operation. With the robot built into the machine, the ARMROID requires minimal floor space. The ARMROID is also extremely easy to use, being fully integrated into the Okuma OSP control, and minimize programming requirements by generating its own motion path using the standard Collision Avoidance Software.

David Fischer:

For tasking in a vertical configuration, Okuma offers the VTM and VTM-YB Series. With heavy duty milling and turning spindles, and up to two meters of swing, these machines are capable of handling large, complex parts. These machines have powerful turning and milling spindles, just like the MULTUS series, providing turning and milling capabilities without compromise, while still maintaining the high level of accuracy Okuma is known for. The VTM-YB is available with a contouring B-axis for doing precision, full 5-axis machining.

David Fischer:

In addition to multitasking turning centers, Okuma also provides machining center-based multitasking machines. Based on the Okuma's highly regarded MU series, these machines provide robust milling capability on a full 5-axis machining platform, as well as robust turning capability to provide complete part processing.

David Fischer:

Thank you for your time, and we're open to any questions you might have regarding multitasking in general, or Okuma multitasking in particular.