Toolcraft's Success Story: UR5e Cobot Boosts Production and Reduces Costs in Medical Device Manufacturing with Lights Out Mfg's Integration
Introduction:
Toolcraft, a small machine shop based in Seattle, Washington, manufactures high-precision parts for aerospace, medical, and defense industries. Faced with labor shortages and the need to increase production, the company turned to Lights Out Mfg to integrate Universal Robots' UR5e cobot into their operations. By automating a complex three-operation machine tending task, Toolcraft experienced a 43% increase in throughput and a 23% reduction in production costs.
The Challenge:
Toolcraft was at a crossroads when a large order prompted the company to add a third shift for 24/7 production. However, the local labor market couldn't provide the workforce needed for the third shift. Toolcraft initially considered traditional industrial robots but found that Universal Robots' cobots, with their ease of use, cost-effectiveness, and no need for a safety cage, were the ideal solution.
The Solution with Lights Out Mfg:
Toolcraft collaborated with Lights Out Mfg, a Certified Systems Integrator of Universal Robots, to automate a multi-threaded part for a medical device requiring three-step CNC machining. The UR5e cobot, with its 30-micron repeatability and built-in force/torque sensing, was perfect for this high-precision task.
The Results:
Within six months of deploying the UR5e cobot, Toolcraft saw significant improvements in production. The company increased its output from 255 parts per week to 370 parts per week and was able to complete a year's worth of production seven weeks sooner. Production costs decreased by 23%, and Toolcraft anticipates an ROI on the UR5e in just 12 months.
Enhanced Capabilities:
The UR5e's force feedback in all joints was instrumental in making the part fit tightly into the CNC fixturing. Additionally, Toolcraft added a part rinsing and cleaning station, utilizing the UR5e to dip parts into a rinsing solution and pass them through an air jet before placing them on a rack for shipping.
Ease of Programming:
Toolcraft's automation engineer took the online UR Academy, which enabled him to program and install the rinsing and drying station without external assistance. Furthermore, the company used Universal Robots' simulator to program the rinsing station offline, allowing the cobot to continue working during the programming phase.
Expanding Automation Capabilities:
With the success of the first UR5e installation, Toolcraft plans to install one cobot per year. The company is confident in its ability to automate tasks on the shop floor, such as tending a horizontal mill, using Universal Robots' cobots and innovative fixturing solutions. Lights Out Mfg's integration expertise will continue to be a valuable asset in ensuring a smooth and efficient transition to further automation.
Conclusion:
Toolcraft's experience with the UR5e cobot and Lights Out Mfg's integration services demonstrate the potential for small to mid-size manufacturers to automate complex tasks, increase production, and reduce costs. The ease of programming, flexibility, and precision of Universal Robots' cobots, combined with Lights Out Mfg's expertise, make them an ideal solution for modern manufacturing challenges.