Modular handling system provides flexibility and performance for Lewmar Marine

Citation

(2001), "Modular handling system provides flexibility and performance for Lewmar Marine", Assembly Automation, Vol. 21 No. 4. https://doi.org/10.1108/aa.2001.03321daf.005

Modular handling system provides flexibility and performance for Lewmar Marine

Modular handling system provides flexibility and performance for Lewmar Marine

Keywords: Handling, Automation

Modular Automation of Birmingham (UK) has supplied an intelligent handling system to the world's largest marine winch manufacturer, Lewmar Marine. The company supplies sail handling fittings and marine equipment for use on cruising yachts, racing yachts and power boats. The handling system forms part of a new manufacturing process, supplied by Hitachi Seiki, that reduces setting times by 200 per cent and lead times from eight weeks down to just two (Plate 7).

Modular Automation has provided a complete intelligent handling system to link four Hitachi Seiki CS40 self-load vertical lathes and a Lorenz gear shaping machine.

Plate 7 Modular Automation has built an intelligent handling system for Lewmar Marine that reduces setting times by 200 per cent and lead times for the company's high-quality marine winches form eight weeks to just two

The system is split into two loops: one for the winch stems and one for the drums. Each machine is linked using Modular Automation's Gullwing Linkline conveyor system which delivers castored pallets to the self-loading lathes.

Each pallet carries a unique electronic tag carrying the description of the component which handshakes with the each machine in sequence, programming it to perform the correct machining for each product variant. This system allows any winch product in the range, from 94mm to 228mm high, to be machined on the same system without any reprogramming or adjustment. This also enables the system to process small batches of product, even single orders.

The modular system also provides link and locate units under each lathe to position the workpiece accurately. Two lathes also have servo turnover units provided as part of the handling system.

The second loop carries the winch drums to the gear shaping machine. Here a Pressflow cartesian robot picks the drums from the Linkline conveyor, then loads, positions and unloads the drums on the machine. This is one of the new range of Pressflow products designed and built by Modular Automation since it acquired the company two years ago. The range has been designed for speed, accuracy and simple programming.

Previously Lewmar had used robot-loaded machines, however this system was unable to cope with the company's increasing demand for its products. This new system allows the company to control maintenance costs, improve productivity, provide greater manufacturing flexibility and achieve the ever-tightening delivery schedules demanded by its customers.

This new system is typical of the innovative way in which Modular Automation approaches all its assembly projects. It uses trusted technology, proven techniques and intelligent engineering to provide its customers with systems that are practicable, reliable, flexible and have short pay-back.

Further enquiries should be made to William Bourn, Modular Automation, Talbot Way, Small Heath Business Park, Birmingham B10 0HS, UK. Tel: +44 (0)121 766 7979; Fax: +44 (0)121 766 6385; E-mail: bourn@modular.co.uk