Lower scrap rates with Ellistat
Joseph Martin chose the APC software Ellistat to automate the setting of its machine tools and improve production quality
"Reduction of the reject rate from 4 % to 1.5 %, spacing of inspection times from 20 minutes to one hour".
History
Joseph Martin, a bar turning company based in Vougy and Bonneville in Haute-Savoie, employs 190 people and specialises in the production of components for the automotive industry. Pierre Challamel, manager of the company's numerically controlled multispindle lathes, is delighted with the results obtained thanks to the implementation of Ellistat's APC software. Machine downtime has been reduced, the OEE has improved, and there has been a clear reduction in rejects. "We have gone from 4 % to 1.5 % of rejects", stresses Pierre Challamel.
The company was looking to reduce its inspection times and optimise its production process. The APC software, developed by Ellistat, enables machine tools to be adjusted automatically from the measurement of a single part. This software, initially deployed in the watchmaking sector, was successfully adapted to Joseph Martin's needs, making the company the first bar turner to use this innovative solution.
Improve operational efficiency and quality
In 2018, the APC software was tested on an Index MS22-6 multispindle lathe, producing components for Volkswagen's DSG gearboxes. A portable PC is connected to a series of electronic control instruments, allowing the measured dimensions to be directly integrated into the software, which calculates the necessary corrections. All the operator has to do is program the new parameters on the machine.
The IATF 16949 standard for quality management systems in the automotive industry requires rigorous SPC training for operators. Each operator must be able to explain to the auditor how he controls his machine using the SPC. Since their last audit, Joseph Martin has had to justify and record all the dimensions measured. "With Ellistat, I can save them very easily", adds Pierre Challamel.
Rapid results and widespread adoption
Since the initial tests, seven multispindle lathes have been controlled by Ellisetting, out of a total of 28 machines. The excellent results obtained have encouraged the company to extend the use of APC to its entire fleet.
"We estimate a significant financial gain per machine equipped, in addition to environmental gains thanks to the reduction in scrap and skills upgrading," explains Laurent Martin, Managing Director. The partnership with Ellistat, based on a win-win relationship, has led to rapid adoption and improved performance of the software.
In 2021, Joseph Martin is a finalist in BFM Business' Grands Prix de l'accélération digitale in the 4.0 category, in recognition of his project with Ellistat..