The company decided that noncutting time had to be reduced. It implemented a process of continuous improvement to attain enhanced performance from its established, three- and four-axis machining centers and turning machines. However, Dunlop realized that it was limited by the inability to use the most modern tooling applicable to the task. It then installed a Matsura MAM-72M multi-pallet machine, which had been able to eliminate setup time, a key factor in reducing lead times by 73%, according to the company.

Machining times also were reduced because the system's high-speed spindle facilitated the adoption of the latest tooling, while prismatic machining allowed several operations to be combined. The high-speed spindle has through-spindle high-pressure coolant supply. The machine has a 210-position tool magazine and a 40-station pallet workholder system.

Dunlop reported that as its experience with the machine accumulates, a "significant" reduction in the large number of different billets needed for machining by older methods will be realized. It is also possible to modify the production schedule without affecting productivity and to reduce stock in progress. There is always at least one billet of the right size available somewhere on the 40 pallets. At the same time, tooling for approximately 400 different parts and variations is being standardized and simplified. Form tools have been eliminated because the five-axis control system, combined with the high-speed spindle, makes it possible to produce contours, undercuts, and other features using standard tooling.

Dunlop Aviation is also enlarging and remodeling its specialist electronics manufacturing unit for aircraft brake management systems. An additional environment test chamber is being installed to eliminate production bottlenecks. The controlled atmosphere assembly lines have been enlarged and new lines installed for the two current major programs: the Eurofighter Typhoon and Dornier 328.

Stuart Birch

Aerospace Engineering May 2000