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I want to tell you about an experience which happened to me recently.. very interesting.
An experience that has put a strain on my nerves and those of my team.
I met a client who produces castings.
I showed him my machines, and explained my system.
I explained how we work, how we face up to problems, which points in my system make a substantial differences compared to other machines.
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And he (like everyone) said to me:
- yes, very nice, but my sector is different
- interesting, but we did a test with one of your competitors and it was not possible to do it.
- I would appreciate it, but we produce small batches
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OHHHHHH…..!
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The usual objections, the usual doubts, the usual fears…
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To tell the truth, not only I promised him the moon but I said also that those who bought my competitor’s machine have already put it in the garden….
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But there is a problem!
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The casting automation system, REALLY WORKS!
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So I wanted to prove it scientifically!
I offered to do a test for him and make it as difficult as possible for us.
Usually when a client wants a test, my requests are the following:
- A finished sample
- 15 raw samples
- See the current work cycle
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THIS TIME INSTEAD…
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I asked for just one raw piece and they explained to me how they wanted the piece.
I hadn’t the possibility to try the work cycle except with my client. I couldn’t see the final piece ( so I didn’t really know the quality my client really needed).
Then I went home and explained the challenge to my family.
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MAKE A WORK CYCLE, FASTER THAN THE MANUAL ONE, BETTER WITHOUT TRYING THE CYCLE, WITHOUT MARGIN OF ERROR, WITHOUT HELP.
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I felt like the coach of Usein Bolt, as if I had told him:
“You’ve got to win the 100 meter race, starting 10 meters behind the others!”
In the company everybody worked with the usual dedication and professionalism: the engineers designed a truly perfect gripper, the mechanics worked the steel with centesimal precision, the assemblers installed the machine with the most suitable tools and the programmer made the MAGIC alive…. And within a few days we were ready for the test together with the client.
The client brought 10 pieces and worked them together.
He came with a look, as if he wanted to say: “ I’VE ALREADY SEEN THIS SITUATION WITH ONE OF YOUR COMPETITORS. THIS MORNING YOU CAN’T PRODUCE 10 GOOD PIECES”.
In practice we have tested the work cycle together with the client, no chance of error was allowed, the stress was burning
The machine was ready, but we had never produced this kind of piece before. We prepared a programme following our experience.
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START
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The first piece was done well, but had some flaws.. So we changed the programme. 15 minutes later:
- The pieces were perfect
- The cycle time was great (3 times less than by hand)
- We did a small MIRACLE…
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WHY?
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The Casting Automation system ALWAYS WORKS.
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Because it is based on 3 points:
- The system is internally designed in Every Detail
- Specific Work unit
- The process does not depend on the Operator
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1. The System is Internally Designed in Every Detail
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The machine was designed and built by a skilled team. My engineers know perfectly well the project and the common idea behind each machine.
Every detail of the machine is built according to a specific statement. Every thing contributes to make the machine perform.
The base, the position of the robot, even the conveyor parts are made in a way to make the collection really different from any other product on the market.
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2. Specific Work Unit
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I spent many sleepless nights in order to find the best solution. We built work units that no one else can boast of today.
Actually, there are some of my competitors who desperately copy all they can.
But there is a problem!
The units are performing so well that everything seems important… my competitors copy even the colours and the most insignificant details. Yes, it’s true, every thing is important, even the painting, also the screw type to use to assemble the units, even the smallest chamfer.
Everything is important because it is the result of an experience grown over the years. It is the result of a continuous development. The competitor who tried the test had no success because a copied tool will never work like mine.
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3. The Process does Not Depend on the Operator
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The whole machine is made to be as independent as possible from the operator. Each unit is equipped with compensation systems, which make programming very easy.
The machine has a specific software so that the cycle self-regulates when decreasing the cutting capacity of the tool.
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HOW DID THE TEST FINISH?
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The client was speechless.
He didn’t know what to say, he was absolutely unprepared for this blockbuster….
A really incredible blockbuster.
Everything depended on teamwork and the professionalism that everyone puts in his work.
I’ve to say thank you to all the guys for the work they do everyday.
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WOULD YOU LIKE TO CHALLENGE ME?
WOULD YOU LIKE TO TEST THE CASTING AUTOMATION SYSTEM?
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I am proposing to you the NO RISK TEST, the same one I spoke about with the AFC line.
THE NO RISK TEST takes place in these stages:
- I do a free evaluation on the cycle time to process your piece
- I prepare an official offer in which I declare I will comply with the cycle time
- We do a small contract committing you to buy the machine in the event the test meets what I promised you in the offer
- I prepare the gripper and tooling required for the test. I prepare the work programme. All without any cost.
- We carry out the test. During the test you can try everything you want. For one day you can produce all the pieces you want.
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Piercarlo Bonomi
The Main Expert in Robotic Cutting and Deburring Machines
