Original Date: 07/13/1992
Revision Date: 01/18/2007

Flexible manufacturing and automation has provided Watervliet Arsenal (WVA) with the capability to meet large increases in demand or a sudden need to shift product mix without a decrease in production efficiency. The Arsenal's manufacturing cells include a Horizontal Machining Cell, a Vertical Turning Cell, and a Vertical Boring Cell. These cells consist of three CNC Horizontal Machining Centers, two Vertical Turning Centers and four Vertical Boring Machines. Each cell is equipped with a mini-computer and rail guided material handling system. These cells have the capacity to perform work which would require 20 machines and an equivalent staff. The total investment in these cells is $17.5 million.

The Horizontal Machining Cell control system is a MicroVAX 3100 with tool and fixture management; automatic data collection; report generation; dynamic system display; and an interface with the DNC system. Its material handling system is a rail-guided vehicle with two pallet transfer arms and a capacity of 12,000 pounds. It has 18 queue stands, and 34 pallets.

The Vertical Turning Cell control system is a MicroVAX 4000 with tool and fixture management; automatic data collection; report generation; dynamic system display; an interface with the DNC system. Its material handling system is a rail-guided vehicle with one transfer arm and a capacity of 6,000 pounds. It has 14 queue stands, 3 load stands and 12 pallets.

The Vertical Boring Cell control system is a MicroVAX 4000 with tool and fixture management; automatic data collection; report generation; dynamic system display; and an interface with the DNC system. Its material handling system is a rail-guided vehicle with one transfer arm and a capacity of 6,000 pounds. It has 18 queue stands, four load stands, and 15 pallets.

Parts manufactured in these cells is of higher quality compared to parts produced through conventional methods. Improved quality was attained due to the combining of manufacturing processes without refixturing, probing capabilities, and continuous monitoring/feedback of the status of the machine tool. The net effect of cellular manufacturing is the increased efficiency of production operations.

These flexible manufacturing cells provided benefits in addition to producing high quality parts. These benefits include a more effective utilization of manufacturing floor space, reduction of WIP inventory, and prompt delivery of the product to the customer.

The versatility of these cells permits the production of a wide variety of cylindrical and prismatic work pieces to extremely close tolerances. In addition to production components, prototype parts are planned to be routinely processed through these cells. The flexible manufacturing cells represent one of WVA's answers to meet the customer's needs for high quality and quick delivery.

For more information see the Point of Contact for this survey.