How Athena Integrates Automation into Our Precision Machining Services
At Athena Manufacturing, we strive to stay ahead of the curve by investing in technology and equipment. Over the last decade, we’ve prioritized automating our processes to respond to customers’ needs strategically and consistently. We’ve integrated robots into a range of our processes, from welding and milling to laser tube cutting, to streamline production and enhance the quality of our parts.
Let’s dive into the advanced automation capabilities we leverage to meet rising demands and tackle high-volume production.
Automation Processes at Athena Manufacturing
The main technology Athena has invested in over the last decade is automated equipment, particularly industrial and collaborative robots that revolutionize how we work. With nine robots in our facilities, we can ensure precision, quality and efficiency in each step of the manufacturing process.
Welding
Our commitment to automation began with welding when we acquired our first cobot in 2014. We now utilize four welding cobots, and one traditional robotic welding cell which have not only improved efficiency but also enhanced the quality of our welds.
Machine Tending
The next technology that we introduced was machine tending automation at our CNC machining centers. This automation allows us to continually keep the spindles turning, reducing downtime and improving the OEE of our legacy equipment. The pick and place robots we implemented also increased the consistency of our part loading, improving the dimensional stability of our machining processes on top of the more predictable output.
Material Handling
We have a number of material-handling robots that load materials into our machine, allowing us to perform many of our operations lights out.
Milling
Our highly efficient milling processes are a result of our state-of-the-art equipment, including our Makino MMC2 24 Pallet Cell with 3 Makino A61NX machines. This equipment features automated pallet changing with 38 pallets and workpiece exchange systems that reduce downtime between setups and minimize manual intervention.
Grinding
One of our standout equipment achievements is our industrial grinding robot. This involved a four-year R&D collaboration with 3M Co., who supplied the abrasive materials used in the grinding tool, and PushCorp, who supplied us with the robot’s end effector. This robot garnered international attention, even earning us a front-page feature in the Wall Street Journal. This integrated system, operated by a joystick, has revolutionized our grinding process by removing manual grinding processes, eliminating human error, and ensuring consistent results.
Laser Tube Cutting
To leverage automation in our shop, we invested in a fiber tube laser with an integrated milling head. This equipment takes raw stock tubes and cuts them to the required size, produces holes and features, and threads the material all in one setup. This used to be a three-operation process completed by different machines and employees across our facility. With the addition of this machine, we were able to combine three operations into one, reducing the number of setups and time on our tube laser products. Our automated tube laser removes human risk from the operation, never missing a single hole or thread, and improves our welding quality by adding tab and key features, allowing for self-fixturing.
How Our Automated Processes Add Value to Customers
As a result of our investment in automation at Athena Manufacturing, we can add value to our customers’ projects in the following ways:
Reduced risk of human error
Even the most highly skilled humans make mistakes. By leveraging automated equipment, we are reducing the need for human intervention, thus cutting down on the mistakes that come with manual operations.
Scalability
Our investment in automation makes Athena readily available to respond during surges in business. We can scale from R&D manufacturing to high-volume production all in one house.
This occurred last year when one of our semiconductor customers requested higher volumes of production. We went from producing about 15 to 20 frames a week to anywhere from 30 to nearly 100 frames a week! We were able to meet this high demand by automating our grinding and welding robots.
Additionally, with our lights-out machining capabilities, we didn’t need to hire additional team members to work overnight to keep up with the increased demand. This cut down on lead times associated with hiring, interviewing, running background checks, and training new team members.
Greater Quality
Automating our machining processes enables us to make parts on one machine, oftentimes in a single setup. Fewer setups mean less room for error, resulting in high-quality precision machined parts.
Automated Sheet Metal Fabrication Services at Athena Manufacturing
Our strategic investments in highly effective equipment and cutting-edge automation tools allow us to deliver high-quality, scalable production volumes. From tight-tolerance aerospace and defense work to high-volume projects in the semiconductor space, we provide consistently exceptional results.
Leverage highly automated precision machining services through a partnership with Athena Manufacturing. Connect with us to learn more about our contract manufacturing services and discover how our cutting-edge processes can add value.