Micro-Matic Finds Efficiency and
Competitiveness in the SNC64G/S

Youngstown, Ohio-based Micro-Matic manufactures molds for various attachments and containers for the medical, automotive, retail and consumer device markets. This includes products for their own proprietary PVC fence line.

Company president Bob Platt is constantly evaluating his business and its need for new equipment. In order to remain a successful competitor, Micro-Matic tries to position itself on the cutting edge of technology. Recently, Bob purchased a Makino SNC64G/S to help the company streamline its processes.

During the recent slump in the economy, the company's new Makino SNC64G/S—along with some careful planning and talented employees—has helped Micro-Matic's business remain intact. With increasing domestic and foreign competition driving lower prices, shorter lead times and faster delivery dates, companies like Micro-Matic are finding that they need to be able to produce products more efficiently than ever to stay in the game.

"We would not be in business if we did not have machines like the SNC64 working to help us reach our goals," said Platt.

Careful Growth [back to top]
In 1972, Platt left his job as a tooling engineer in a large molding company to open his own tool shop. The company grew slowly and conservatively over many years, using some automatic and CNC machines to do work for automotive suppliers. Five years ago, Micro-Matic's biggest customer was bought out, taking that work with them. This would have been a huge blow to the company and its 21 employees had they not been investing in leading edge technology.

Since then, not only have they expanded their machining area, but Platt has also started another business venture related to Micro-Matic. The company, called American Way Manufacturing, makes components for a PVC fence product line with its injection molding machines. American Way utilizes Micro-Matic's expertise to design and build their molds. Platt is working on his eighth patent for components used in assembling the fence.

Platt puts careful thought into the purchase of new equipment for his businesses. He realizes the impact that technology has had upon past growth, and he tries to make every dollar count by doing a lot of research prior to purchasing.

In addition to considering a company's reputation, technology and longevity, Platt bases much of his purchasing decision on his prior experience. The first CNC machine Micro-Matic purchased was a Makino, and it is still in use on their shop floor today. It has not had any major maintenance problems, and still cuts within tolerance.

"Makino's had a flawless reputation for many years, and we bought this high speed milling machine taking into consideration the good results we've had with their equipment in the past," said Platt.

Platt also takes a look at a machines capability for automation and flexibility, with speed of cut and rigidity also vital. "When I saw the demo on the SNC64, I was sold on the machine instantly."

Process Improvement [back to top]
Platt bought the SNC64 to perform the intricate cutting of hard steel. But he has also found success in the milling of graphite. Micro-Matic has noticed cycle time reductions of 35 percent for steel and carbon because of the fast feeds and speeds on the SNC64. Part accuracy—holding tolerances of half a thousandth for 90 percent of their work—has also improved dramatically.

Just a few years back, Micro-Matic would have to rough the part, send it out to be heat-treated and then EDM, a time consuming process for the work that they did. On some parts, they also used to bench polish the corners out with emery paper to get a better surface finish on graphite applications. With the new machine, they have noticed a major decline in required polishing time.

"One of the biggest things the SNC has helped with is eliminating more of the EDM process—the polishing time and the bench work on all of our inserts—many of which are hardened steel applications," said Dan Fitchet, Micro-Matic CNC manager.

"Often times—depending upon the geometry and complicity of the part and the customer's finishing requirements—we could put a light polish on it and keep it out of the EDM department. That has been a big bonus for us."

Getting Products Out The Door [back to top]
With faster speed and throughput, along with the elimination of bench work due to the superior finishes achieved from the Makino SNC64, Micro-Matic gets things out the door quicker.

Recently, they got a job making the plastic injection mold for a clip used in the child care industry. Getting the job depended on delivery time and therefore how fast Micro-Matic could cut the part. The SNC64 was able to cut the cavity from a solid, rough and finished it within 35 minutes, while eliminating three full passes and polish time.

Micro-Matic was able to run the machine overnight and the application was a success. Before getting the SNC64, Micro-Matic would not have been able to even competitively quote this job, much less machine it with the quality and speed needed for completion.

"I would say that the machine has saved us at least 30 percent overall on our standard milling processes. There are many things we do now that we would not have been able to do six years ago. We would not be able to cut hard steel, let alone do it quickly, accurately and with detail," said Mark Oliver, Micro-Matic programming manager.

Similarly, Micro-Matic machined a recent mold for a consumer device and saw cuts that were four to six times faster than what they previously achieved. In that application alone they saved 60 percent on polishing time.

On both graphite and steel applications, Micro-Matic has not only increased cycle times, but is able to add enhancements by using smaller tools. They are making pieces that are even more defined, which they could not do before.

To make the most of the SNC64's capability, Micro-Matic schedules a project so that they may feed as much work through the machine as they can. "The machine allows us to run automatic longer—with faster cuts, better finishes, and savings in labor," said Platt.

They are able to take small cutters and really detail the area they are going to burn on the electrodes. With steel, they will finish everything on the SNC machine with multiple daytime setups and overnight runs.

Platt has found that they can achieve more throughput with fewer hours, allowing Micro-Matic to do more work with their skilled labor. Overall, this technology allows them to compete better on their one shift of operation.

Easy Installation [back to top]
For Micro-Matic, setup of the SNC64 was very successful. They believe Makino's technology transfer training was straightforward, and their staff caught on quickly.

"It was a very good move to get this machine. It has done everything we have needed it to do. We have had the best turnaround on training that we have ever had on any equipment we've purchased," said Platt.

"We have had other equipment come in where it has been six months before I really felt that we were getting all the capabilities from the machine. In one week with the SNC64, we were cutting production cavities. And two weeks after that, we had made a 20 percent overall improvement. It was an amazing turnaround."

Oliver says others are also awed by the speed, accuracy and overall quality provided by the SNC64. "What astonishes me most is how many people this machine impresses, and how many people—employees and customers—are positive about it. They know that this is what is making things happen. This is probably the only thing I've ever been involved with that actually does what they say it will, and I'm surprised about that."

Hidden Value [back to top]
While good equipment is crucial to an operation, the hidden performance of exceptional machining lies with the controllers and programmers who work with the machinery. At Micro-Matic this is no exception as these folks control the efficiency of the machining.

The programming and CNC departments must work hand-in-hand. Both Fitchet and Oliver have design backgrounds, enabling them to visualize the part in their heads while working with engineering to plan out successful cuts. A lot of thought goes into how the process is addressed and much testing is done. The staff is experienced—whether cutting graphite or steel. They use that experience and prove that something will work before committing to a job.

"You take this behind-the-scenes cooperation—combined with the machine technology and unbelievable rates of cut—and it is a great marriage," said Platt. "The Makino SNC64 is a fantastic partner in the process."

"We are very satisfied with the machine and the capabilities it has brought to our company. The process has benefited our company as a whole—from sales to the machine operator," said Fitchet.

Keeping an eye toward the future, Platt is looking at an approach of standardizing a robot and the loading of two EDM machines as well as a five-axis machine. "We're working diligently to make sure that we stay competitive," said Platt. "With the equipment and technology Makino offers, I cannot see why they would not fit in with the future of Micro-Matic."

Micro-Matic Tool, Inc. can be contacted at 220 Victoria Road, Youngstown, Ohio 44515-2090. Phone: 330-793-7051 FAX: 330-793-7065.

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