Skills at the Algram Group are concentrated on plastics mould toolmaking and prototyping. The company's machine tool buying policy is based on removing the routine machining element from the skilled toolmaker's brief. Which is why Algram has recently acquired an Ingersoll Center 4000 EDM cell.
The Center 4000, supplied by Mitsubishi EDM in Milton Keynes, is equipped with Erowa systems for robotised pallet changing and automatic tool changing.
Capacity is for four pallets and 102 tools.
Before the acquisition of the Center 4000, Algram relied on four manually-operated EDMs.
When it came to considering modernisation, it was felt that it was not worth updating the low amp EDMs with retrofit automatic tool changing (ATC) and palletisation.
'We went for the Ingersoll machine with the Mitsubishi controller and Erowa tool and work handling systems,' said Danny Wilkinson.
'For us, it was quite a jump technology-wise, as we had had no previous experience in operating CNC EDM.' It must be emphasised that the company is no stranger to CNC.
Algram operates nine CNC millers, and the toolmakers regularly perform their own CNC co-ordinate measuring machine (CMM) work.
'In choosing which CNC EDM machine to buy, we sought complete automation package solutions rather than a discrete machine.
We narrowed the choice down - in terms of technology and service - to Mitsubishi and one of two Swiss suppliers,' said Danny Wilkinson.
'We were looking for good after-sales support, technical back-up - which was essential for a first-time CNC EDM buy - and warranty.
Essentially, in these respects, there was no difference between the two suppliers.' 'Ease of programming was a consideration,' but in reality, Danny Wilkinson said it was only a question of mastering a Olearning curve.
'What decided us on the GBP125,000 Center 4000 package was Mitsubishi's willingness to offer a rental period.
We were able to build up training and experience in this period on a low overhead basis, so when we purchased the Center 4000, we achieved a quick payback.' In choosing the Center 4000, Algram was seeking flexibility as well as unmanned operation.
As with the earlier manual EDMs, the larger electrodes used in single-impression die work will be changed manually.
Much of the EDM in the Center 4000 will be multi-impression work, maybe requiring up to 36 separate tools for each die, and which will make more use of palletisation and ATC.
Sparking programs with in-process feedback control to optimise power consumption and minimise electrode wear are set up in the CNC.
Work is scheduled in and out of the Center 4000 work area through the robot controller which can also be interrupted or over ridden.
Algram's productivity target is to achieve an 80% machine utilisation, based on 7-day, 24h operation, by the middle of this year.
The Center 4000 had been installed in July 2000, and utilisation had passed the 50% mark by January.
The workload on the Center 4000 was still growing.
Three of the older manually operated EDMs have been disposed of.
'A year ago, without this machine, we had a production bottleneck,' said Danny Wilkinson.
'On a five-day, 10h basis, the Center 4000 can do the work of two of the older EDMs.' The company has also acquired a Mitsubishi RA9 CNC wire EDM, initially on rental.
Now that the EDM operators have had some experience with the RA9, the plan is to equip it with automatic wire feed.
Danny Wilkinson1s team is in the process of evaluating the machine.
It will make an important contribution to factory lead-times, as currently all of Algram1s wire edm needs are subcontracted out.
'Since Algram became a member of the KeyMed group, we have been consistently investing œ3/4m per year in new plant and technology,' said Stephen Brown, Managing Director of Algram.
'Toolmakers are very scarce, and it is our intention to make the most use of toolmaking experience, which is why we invest in high technology equipment.
We can therefore free our toolmakers from routine operations, like machining, allowing them to concentrate on skilled mould tool assembly, fitting and finishing.' The company has invested extensively in CAD/CAM and now has four modelling seats and six machining seats.
DelCAM systems are used for off-line programming, including 3D machining, to which the nine CNC millers, the Center 4000 CNC EDM and the Mitsubishi RA9 CNC wire EDM machines are hooked up.
A CATIA seat is included for automotive work as well as AutoCAD and SolidWorks.
Some 40% of Algram1s business is in automotive work.
The company concentrates on providing a 'one-stop-shop' in that it supports its customers with full engineering component design, mould tooling design, prototyping, toolmaking, vacuum and injection moulding, finishing, painting and assembly.
Customers include Rolls Royce Cars, Aston Martin and Jensen for low volume mouldings used in trim and panel work.
Work batches range up to 15,000 - 20,000.
Stephen Brown anticipates Algram turning over some œ5m in the current financial year.
Growth over the last 12 months has been at the rate of 25% and the company currently employs 118.
Injection moulders used at Algram include Arburg and Krauss Maffei machines up to 2kg shot weight.
Vacuum forming machine capacity is up to 2m by 1m.
Algram also uses CNC routers for panel trimming.
Non-automotive work includes components and sub-assemblies for medical equipment, aerospace and electronics.
'Our company history is in prototyping,ý' said Stephen Brown 'We have grown to take on repetitive work and we have no fear of larger volumes.
We have some 200 active customers and our plan is to turn over œ10m by 2004.'
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