One issue military aerospace customers frequently face is long manufacturing lead times. These companies require products quickly but usually need the capability of a full-scale, sophisticated production facility where ramp-up times are considerably longer. Generally, their volumes range from as few as three, but can be as high as 1,000 units annually.
Working in a low-volume, high-mix, high-complexity model, where maintaining product repeatability is extremely difficult, Ben Machine has become a leader, with innovative methods to reduce lead times. Here are a few examples:
Vendor-Managed Inventory (VMI)
Given Ben Machine’s business model of repeatable low-volume, high-mix production, the implementation of a vendor-managed inventory system is a proactive step. In a VMI setup, Ben Machine manages the customers’ inventory based on forecasting data. This ensures seamless product availability, making lead times negligible.
Here are the key advantages:
- Reduced Inventory Levels: We hold the inventory, allowing the customer to maintain lower stock that is off their books and better for their working capital.
- Increased Responsiveness: We can immediately adjust production to meet fluctuating demands by reacting to customer forecast changes before they realize what’s happened.
- Enhanced Adaptability: Our AI-enhanced management systems allow us to respond “on-the-fly” to shifts in demand, which is crucial in dynamic industries.
We actively implement this adaptable solution to support our clients’ needs.
Engaging High-Level Machining Tools
Ben Machine uses advanced equipment in its production processes, such as 5-axis, 8-axis, and 9-axis machine tools, to maximize efficiency. The goal is to complete as many operations as possible in one setup.
Our workflow is streamlined through a proactive approach to programming tasks. Even before the job reaches the machine, all programming is completed as soon as we receive the order. This principle extends to quality checks using a 5-axis Coordinate Measuring Machine (CMM). We prepare the CMM programming upfront, so when complex parts, which can take hours to inspect, come off the production line, they are immediately ready for inspection. This approach eliminates delays in programming, ensuring a quick transition to the inspection phase.
By adopting these practices—advanced programming, efficient use of CMMs, and effective inventory management—we significantly reduce the processing time it takes to complete a product.
Automated Inspection Reports and Documentation
In the AS9100 environment at Ben Machine, we streamline the documentation process for inspection reports. Automating these tasks upfront ensures everything is in place before production begins. Software enhanced by artificial intelligence continues to progress and we progress with it, allowing for automatic drawing feature extrapolation and secondary compliance reviews that speed up the process of preparing documentation. All of this means customers won’t face any delays later, keeping the time required short and efficient.
Engaging High-Level Programming Tools
Aside from supporting documentation efforts, Ben Machine is actively using AI to enhance its operations. Our facilities include cutting-edge, simultaneous multi-axis machines that can consolidate multiple tasks, previously spread across different machines, into just one or two processes on a single machine. While we have optimized the machine’s runtime, the real opportunity for improvement lies in reducing downtime associated with programming and machine setup.
Currently, innovative AI tools are being developed for multi-axis machines. These tools are from prominent companies that comply with ITAR and CGP regulations. Ben Machine is collaborating with these companies to ensure that its operations are cutting-edge and compliant with the highest industry standards. This collaboration will reduce the time required for certain operations from two days to just half a day, demonstrating a commitment to continuous improvement.
Tool Setting
Ben Machine has a dedicated tool room equipped with all necessary tools and specialized staff who prepare these tools in advance. This preparation ensures that machinists spend minimal time setting up when parts reach the machine. While this tool setting process is standard in production environments, it’s rare in non-production environments with low volumes and constant change. By implementing these strategies, we mitigate longer lead times and improve efficiency.
Streamline Your Manufacturing Process with Ben Machine
Ben Machine has adopted several innovative strategies to enhance efficiency and reduce lead times in its production process. We’ve implemented a vendor-managed inventory system, allowing suppliers to oversee inventory levels directly, thus optimizing stock management and ensuring the timely availability of materials. Adopting high-level machine tools has contributed to faster and more precise manufacturing capabilities.
Automated inspection reports help maintain quality control by quickly identifying defects and reducing manual inspection time. Additionally, using AI in our processes aids in predictive maintenance and decision-making, improving overall operational efficiency. Tool setting automation further reduces setup times and potential human error, streamlining the production process.
Partner with Ben Machine for unparalleled efficiency and speedy manufacturing delivery. Collaborate with a team dedicated to meeting your design and production needs swiftly and effectively. Let’s innovate together!
