For AFAB Precision Machining of Lake Forest, Calif., the foundation for success is built on a service-oriented philosophy that steers their long-term commitment to exceed client expectations. They firmly believe that a customer’s success is their own success.
In order to achieve mutual benefit, AFAB knows they must drive internal innovation. They recently did so with the purchase of a Makino a51nx horizontal machining center with a 12-pallet MMC2 system that has cut cycle times in half. AFAB knows that having an operator stand in front of each machine is no longer a competitive way of doing business. For AFAB, the journey to innovation and success lies in automation.
“We have always believed in a customer centric philosophy, following our 4 C’s methodology; Customer Service, Confidence, Capability and Commitment. The Makino system has added a 5th C through increased Capacity,” said Larry Campbell, President of AFAB. “The Makino provides the flexibility and competitive production run pricing our customers deserve.”
A Vision for Automation
AFAB was founded in 1971 by Larry’s father, Joseph Campbell. Larry grew up working in the business with his dad, getting his start helping to deburr injection molded parts. He came up through the ranks as a machinist, before taking over the business in 2008, when Joseph retired. Back in their early days, the company used conventional machines. But by 1987 they had purchased their first CNC machining center and have continued strategically adding to that technology. As president, Larry developed a vision for the company that would incorporate lean principles and automation, helping AFAB to continue to grow and remain competitive.
“To prevent customers from offshoring, we need not only the proximity to the customer, but the ability to give them good parts at a competitive price. Our Makino system allows us to achieve this.”
Today AFAB specializes in precision, CNC turning and milling of plastic, aluminum and stainless steel parts across a variety of sizes, applications and industries. Their dedicated and highly skilled engineering and manufacturing team strives to apply innovative solutions to each of their projects, “doing it right the first time, and on time.” With a customer base that is primarily in the medical industry, accuracy, quality and finish are always top of mind.
AFAB had already realized the benefit of setup reduction that comes with using multi-axis horizontal machining centers, but knew they had to further increase capacity and invest in just-in-time production capabilities to meet the volume requirements and price pressures of their customers. One of AFAB’s customers shared with Larry that their number one supplier had employed a flexible manufacturing system to remain competitive. Happy with their latest 5-axis HMC investment, AFAB began investigating opportunities to tie that machine to an automated system in order to further reduce costs and setups. They wanted the ability to quickly respond to customers, whether they required five parts or 10,000 parts.
AFAB began implementing automation with the supplier of their existing horizontal machining center, but the situation of dealing with multiple vendors soon became overwhelming, creating confusion, conflicts and uneasiness. AFAB pulled out of the commitment. Single Source Technologies (SST), a national distributor of machine tools, related consumables, tooling and EDM supplies, approached AFAB and recommended a Makino a51nx horizontal machining center and MMC2 pallet-handling system.
“We were impressed by the knowledge that SST demonstrated and felt comfortable working with them, based on the sales representatives’ knowledge of the industry,” said Larry. “More importantly, they offered a turnkey solution for their flexible manufacturing system and would coordinate all elements of design and installation.”
That information, combined with financing from Makino’s Capital Services group, helped AFAB better visualize the return on investment. They purchased the a51nx and 12-pallet MMC2 system.
Newfound Flexibility
Prior to installation, several AFAB personnel went to Makino’s Mason, Ohio, facility for training. They learned not only how their new system operated but also advanced machining features such as managing tool life.
“With our flexible manufacturing cell, we have been able to achieve 100 percent utilization rates or 22-plus hours of production each day.”
“In the past, other manufacturers trained us on clamping parts and programming when we purchased their equipment,” said Chad Jackson, production manager at AFAB. “But Makino taught us so much more—and this was all done on the same machine that we had purchased. We felt that it was an exceptional introduction.”
Not long after the system was up and running, a Makino representative visited AFAB for post-production support, where he provided additional training and consulting. He printed a report listing 25 personalized recommendations to further improve the machining system.
“He went over the software and remote monitoring—analyzing and optimizing what we were already doing,” said Jackson. “It was like buying a high-end car and having them come to your house to consult on vehicle operation. It was amazing how much information we were given. And today, should we call with a question, they are always responsive and helpful. It has been everything you’d expect from a top-tier supplier. Our impression of Makino was first and foremost based on the equipment, but we were also impressed by the people we’ve been involved with. Everything has exceeded our expectations.”
AFAB says that system deployment happened at breakneck speed. They have become very comfortable with their new flexible manufacturing system, and have been able to use it to improve their quality, reduce labor costs, and achieve the flexibility to supply customers with just-in-time delivery of their varied part requirements.
“With our flexible manufacturing cell, we have been able to achieve 100 percent utilization rates or 22-plus hours of production each day,” said Jackson. “And across many different parts, we have easily experienced cycle-time reductions between 25 and 50 percent, while repeatedly achieving tolerances of 0.0002 inch, which is critical to our medical part requirements.”
“We have easily experienced cycle-time reductions between 25 and 50 percent, while repeatedly achieving tolerances of 0.0002 inch, which is critical to our medical part requirements.”
On one particular part, AFAB’s customer first looked at sending that part to be cast. However, they weren’t sure the tolerance requirements could be met. On the new flexible manufacturing system, the quality of that part has been proven.
“That medical lamp base previously took 17 minutes to complete the first operation. We can now finish that operation in just eight minutes,” said Jackson. “We estimate that we are saving at least $100,000 per year with the cell by eliminating these repeat setups. And best of all, the system has the precise machining capability to help us achieve better performance. We used to have to rely on the operator loading parts correctly to achieve required tolerances, and we would triple-check before hitting the ‘start’ button. But the nature of this palletized system allows us to relax, knowing it is correct. We appreciate how everything runs so consistently.”
Jackson credits most of this to the quality, construction and features of the a51nx. AFAB was impressed by the stepped-axis design, roller-type linear guides and robust single-base casting design, all of which offer extra rigidity. They are confident that these features have contributed to part quality, as has the chip removal. AFAB appreciates that the system helps them better track tool life.
“We estimate that we are saving at least $100,000 per year with the cell by eliminating repeat setups.”
“The MMC2 shows the operator how much a tool has been run, so we are managing that much better and are really getting a handle on our consumable costs,” said Jackson.
Managing their catalog of parts through the flexible system has also become much easier. If a customer phases out a part but then comes back months later asking for it, the cell can call it up and run the part without delays. The flexible manufacturing system has also enabled AFAB to reallocate their labor, making them more competitive.
“We feel that the technology hasn’t eliminated jobs but instead has changed them,” said Jackson. “We don’t necessarily work harder, but work smarter, as operators spend time programming machines instead of using their hands like they did in the past. With this comes a demand for the technology to stay cutting-edge. To be competitive, job shops must add better machining centers, better software, cutting tools and insert technology. We have that with our flexible manufacturing system.
“To be competitive, job shops must add better machining centers, better software, cutting tools and insert technology. We have that with our FMS.”
“I’ve used equipment from other manufacturers, and this is the first time I’ve had a brand-new machine with so few problems. I’m very impressed. The quality is outstanding. I’m really happy with the system, and we’ve been running the heck out of it.”
AFAB is currently looking to employ key learnings from the automated cell into other areas of the business in order to improve workflow and inventory across all areas of the shop floor. AFAB is also in the process of implementing additional tool-life monitoring and broken-tool-sensor management functions to enhance lights-out production.
Driving Innovation
AFAB personnel continue to add applications into the cell’s MAS-A5 control system in order to expand automation. Company personnel have no doubts that this flexible technology has the potential to quadruple business.
“We take pride in producing the highest quality parts with the fastest turnaround at a cost-effective rate in order to facilitate customer innovation.”
“As we expand into new markets, we hope to increase our investment and add an additional flexible manufacturing system with 5-axis capability,” said Larry. “We want the capability to grow and to service additional customers. We feel that this will allow us to not only machine more complex parts more efficiently but also improve our competitive advantage. The Makino system differentiates us and gives us the freedom to try new things and achieve continuous improvement.”
This continuous improvement ties directly to the company’s mission. What matters most to AFAB is their commitment to customer success.
“We take pride in producing the highest quality parts with the fastest turnaround at a cost-effective rate in order to facilitate customer innovation,” said Larry. “We are able to achieve this through high-performance technology. It allows us to grow and innovate and to find new ways to service our customers.”
“As a company, we aren’t happy standing still. We want to work with companies driving innovation to improve people’s quality of life.”
AFAB wants to be known for their quality, customer service and innovation.
“We make parts that save lives,” said Larry. “If they are not done right, there are consequences, so our machinists take their jobs seriously. You can certainly make things quickly, but if you don’t have quality, you are wasting your time. With Makino, quality is not an issue.
“As a company, we aren’t happy standing still. We want to work with companies driving innovation to improve people’s quality of life.”