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KIWA Japan
CHANGING SHAPE IN A DOWN ECONOMY

New England shop moves to Horizontal Automation in Defense

With winter 09’ well underway in New England, ushered in by perhaps the worst economic downturn in over 50 years, things have cooled down dramatically.  The effects of recession are palpable and hang heavy in the air, until the plain front door of Proteus Manufacturing opens wide and you are fully struck by the drone of high speed equipment and the smell of machined metal.  Then you realize that despite the economy, some shops are still thriving – thanks to automation and the demand for highly precise parts in industries such as defense.

In Greek mythology “Proteus” was a sea god who had the ability to change shape at will.  Judging by the nature of the work here, in addition to the flexible, progressive attitude of the owner and his employees, this 30 + person precision machining shop lives up to its namesake.

Shaping a future through quality
Proteus is located on 44 Sixth Road in an industrial park in Woburn, MA in a 20,000 s.f. facility headed up by Mr. John Tamulynas III, President, whose love for cutting metal and taking on challenges began in the late 80’s when he was an independent machinist contractor making prototypes.  Tamulynas explained how the company has indeed changed shape over the past 10 – 20 years:  “In 1990 as JT Engineering we got our first CNC Milling machine.  Originally we did a lot of prototype work and small quantity production.”

“Over the years we grew steadily and took on precision manufacturing, which is prevalent in our market – especially for the medical industry,” said Tamulynas.  “Medical is a staple in New England but it is also a competitive sector.  As we grew in the precision area we started taking on other high-tech prototype work such as sophisticated optical devices used in the defense industry.

“That’s when we made a big breakthrough” explained Tamulynas.  “At first we were doing a few of these parts, then 20 to 30 a week, which quickly shot up to 100 a week and more.  In 2001 we moved into a 5,000 s.f. facility.  We’ve since added 16 employees in 14 years and the defense industry has kept things booming.”  Finally in 2008 Proteus moved into their current 20,000 s.f. Woburn facility and they are now running 2 shifts, plus overtime, even amid the down economy.

Some of the primary defense components Proteus Manufactures are mechanical housings for optical cameras, lenses and assemblies.  The work is very intricate, requiring extreme precision machining in primarily aluminum to tolerances that are routinely in ten thousandths of an inch.  Of course, this kind of precision requires extensive testing, inspection and quality control.

Quality cannot be overemphasized at Proteus.  It is a constant thread that runs throughout the organization at all stages.  They have a comprehensive quality audit program with a full complement of equipment and procedures.  Every job is followed via a job jacket that moves through the shop every step of the way.

“Our quality is excellent”, claims Tamulynus.  “We take a great deal of pride in the parts we make.  If you place a part we made beside someone else’s, you can see the difference in the details and finish.  Even if our parts are to be hidden within a final assembly, we want those parts to shine, as a matter of principle.”  Tamulynas continued, “We go above and beyond for our customers.  We provide full assembly services and take pride in applying a high level of personal attention in our business – even to the point of delivery.  In fact, whenever possible we hand delivery parts to our customers.”

Proteus’ proactive approach to quality works, as the company claims they are consistently at the top of their customer’s quality ratings.  “I am very proud of our employees.  We have a great team – they are very self-motivated and devoted to excellence.  Our results prove that out,” said Tamulynas.

Leaping Horizontally
Success however does come with its share of challenges.  With increased orders, Proteus was faced with the logistical problems of having to produce more product without hiring more people, or perhaps without purchasing more equipment such as vertical machining centers, to perform the multiple operations required on their parts.

“We are really at a crossroads and were wondering how to address the problem,” said Tamulynas.  “We discussed our situation with our machine tool supplier Methods Machine Tools, of Sudbury, MA who we have relied on heavily throughout our company’s history.  They recommended that we transition from multiple VMC’s to an automated Horizontal Machining Center.  At first, we were concerned that a move to horizontal might be risky.  How much throughput could we achieve?  How much set up time could it reduce?  How difficult would it be for our machinists to run and so on?

Methods really knows our operation inside out.  They were convinced that a Kiwa Japan KH-45 Horizontal Machining Center would take us to the next level.  To my surprise, the impressive, full-featured performance package of the KIWA horizontal solution was more affordable than I had anticipated.  We have always trusted Method’s advice, so after further review and demonstrations, we decided to take the leap to horizontal and had the new HMC installed late summer of 08’.”

Proteus purchased a KIWA Japan KH-45 full 6 APC model.  However shops can invest more conservatively with KIWA Horizontals by utilizing their exclusive in-the-field expandable tool and pallet technology, which easily allows a shop to expand as their business grows.  For example, shops can start with a base 2-pallet machine with 120 tools and expand to a 6 or 8 pallet machine with 220 tools.  “We are currently using 60 tools and 4 pallets but we are already planning to fully utilize all 6 pallets for increased production,” said Mr. Bill Burris, General Manager.

With 400 mm pallets, a work envelope of 29.5” diameter x 39.4” height and an x-y-z stroke of 25.2” x 24” x 26.8”, the KIWA offers and exceptionally large travel and work envelope for manufacturing versatility.  And its rigid, stepped-base and column casting design, box type bed, over 1G acceleration, 12,000 rpm spindle and exceedingly fast tool changer provide the speed and agility to reduce Proteus’ cycle times.  The manufacturers states a tool-to-tool time of 0.9 seconds and chip-to-chip time of 2.8 seconds.  The KIWA KH-45 also features a hydraulic posi-lock pallet clamping system which ensures reliable clamping and accurate machining.  In addition, it features and industry standard Fanuc Control, for operator ease of use and familiarity.

Less time, more opportunities
As it turns out, Proteus was very pleased with the horizontal leap, primarily due to how the KIWA KH-45 has reduced cycle time, moved them into lights out automation and freed up more spindle time for other previously strained operations.

According to Burris, “in the first two roughing ops. on one of our main machined components made of aluminum, the KIWA has reduced the cycle time from 42 minutes to 28 and the pallet system has allowed us to go from one part to 4 parts at a time and run lights out.”  “In the roughing procedure there is an incredible difference – it’s like night and day.  And you don’t need to clean chips out like in vertical machines.  The conveyor system on the KIWA works great as well,” added Burris.

The KH-45 features a clever, efficient chip conveyor disposal design that is fed from the front or side, and continuously removes chips from the machining operation.  Burris explained that the transition into horizontal has been a fast, easy one, by reducing set up time and providing them a much more efficient way to make their parts.  “With the horizontal we can work on 4 sides of the tombstone, doing multiple operations on different stations.  We can load more in the machine and utilize our tooling better.  By putting 4 to 5 jobs in one machine, we have opened up other spindles on other machines, creating more overall versatility and increased productivity throughout our operation,” said Burris.

Tamulynas, who is preparing for more growth on the horizon through other new developments, was thrilled as well.  “The KIWA Horizontal is now doing the work of 3 VMC’s.  It has been extremely reliable – a phenomenal success,” beamed Tamulynas.  “Now that we have gained more hours, we can grow into new areas.  We are now planning to purchase a second KIWA as well, and we’ve only had the first one in production for 4 or 5 months.

After pressing Tamulynas for more details on new growth areas, he imparts some exciting news – more challenging opportunities are being scoped out in the microwave field and high-end filters for the wireless industry, as well as thermal imaging optics for homeland security.  When leaving Proteus you’re attitude is adjusted and you are inspired again.  Manufacturing is alive and the future is shaping up great after all.

Proteus Manufacturing www.proteusmfg.com 781-939-0919
Methods Machine Tools, Inc. www.methodsmachine.com 978-443-5388