Integration Services

Single Source Advantage
Makino is uniquely qualified to be your single
source for developing the most effective solutionthat will reduce the cost of machining a part.
Makino Integration Services takes “primecontractor responsibility” for the complete
integration of machining technologies, third-party
equipment, material handling, applicationengineering, fixtures, on-time delivery, on-site
installation, successful test runs, training and postproduction support.
To remain competitive in today's market,
manufacturers must reduce labor costs, increase
throughput, ensure and even enhance part quality,and yet remain flexible enough to adapt to quickly
changing volumes, designs and products. No othermanufacturing process can achieve all of thesegoals as well as automation. Makino Integration
Services evolved directly from the ever-growing
need for seamless automation and the fierce
pricing pressures manufacturers face in the global
economy.
Makino has been developing automated solutions
for manufacturers around the world since the mid1990s. Today, no one is better positioned toprovide you with the equipment, skills andmanpower necessary to effectively implement
automated solutions for competing in the global
marketplace.
Our extensive integration experience, coupled with
our production machining solutions andapplications' engineering support, make us theonly company you need for an automatedproduction system solution. We've createdeverything from simple cells with a single machine
and a robot loader—to large systems, consisting of
Makino machining centers, parts conveyors, robot
and gantry loaders, automated assembly andinspection equipment, parts washers, parts
marking and more.
We coordinate all operator controls, providing acommon human-machine interface platform andnomenclature. A Makino Integrated Services
solution guarantees a tightly integrated
manufacturing system with startup/shutdown
procedures, alarm recovery, mechanical interface
and part tracking.

While our solutions are automated, our service
isn't. Our service teams include experts in every
facet of automation integration. We customize ourservice to meet your unique and specific needs byproviding a single source of dedicated project
management and site coordination services,
backed by the Makino staff of project, mechanicaland controls engineers. A Makino automatedsystem is a total system solution.
With Makino taking prime contractor responsibility,Integration Services frees up your time andresources that can be allocated elsewhere. Makino
Integration Services ensures the smoothest
possible installation of multi-vendor projects. As asingle source, Makino provides fast resolution ofyour most challenging issues. As a company withextensive process and operational experience, wedeliver the best solution—never compromising on
quality or efficiency.

Automation Goals and Needs
One of the first benefits that comes to mind when
considering automation is the possibility of reducing
manual labor in order to lower cost per part. This iscertainly one of the key benefits of implementing
automation, but there are many more advantages that canhelp you meet your operational and business goals.
Additional benefits include:Ÿ Eliminate ergonomic issues: Some parts are heavy andcan be difficult to handle. Even if the part is not heavy,
many workplace injuries are the result of repetitive
motions that can be avoided with automation.
Ÿ Free up operators: Instead of spending their time loading

and unloading parts, automation makes it possible forthem to attend to higher level work such as inspection
and tool setting.
Ÿ Improved part quality: The consistency of how a part isloaded into a fixture can impact the quality of the parts
manufactured. Automation can increase thisconsistency.
Ÿ Increased throughput: If the machine faults because of a

misloaded part, time is lost as the operator corrects themistake and reloads the part. Automation reduces thepossibility of misloads that stop production.
Ÿ Increased OEE (Overall Equipment Effectiveness): Theavailability, performance, and quality can all be improved
with automation, resulting in a higher OEE score.

Additional needs manufacturers are looking for when
implementing an automation system include:Ÿ Complete turnkey process with SPC runoffŸ Integration of all material handling equipment (pedestalor gantry robotics, conveyance, input and output material
handling, etc.)
Ÿ Integration of “pre” or “post” machining processes (partmarking, leak testing, parts washer, minor assembly)Ÿ Flexibility to redeploy for future production requirements

Automation Options
Ÿ There are many different components and combinationsof automation elements that can be utilized to create theoptimum system. Makino has the experience andknowledge to guide you through which ones are best foryour needs. Some of the aspects of automation that
Makino has successfully implemented over the years
include:Ÿ Pedestal robot
Ÿ Toploader robot
Ÿ Conveyor systems
Ÿ Vision systems
Ÿ Gripper indexing
Ÿ Gripper vacuum
Ÿ Inspections systems
Ÿ Part blow-offŸ Part gage/reject stations
Ÿ Input/Output conveyors
Ÿ Robot deburringAutomation Essentials
For an automation system to be successful, there
are several important features which are neededon the machine tools integrated into the system.
First, flexibility is needed to control the fixture
clamp/unclamp sequence and pressures throughprogramming. This makes it possible for an
automated load/unload operation to simulate an
operator performing the task. Makino provides aFixture Hydraulic Unit (FHU) that delivers
continuous variable pressure with the ability toprogram clamp/unclamp sequences to dial in yourpart process. This feature enables you to programa part unclamp/clamp within the work zone tostress relieve a sensitive part between a rough andfinish cut without stopping the process for manualintervention.
In the pallet stocker area of the machine tool, it isimportant to have auto doors to synchronize withthe robot. The robot can be used to rotate thefixture to access multi-sided tombstone fixtures or
the machine can be equipped with a power indexer
that will automatically rotate the pallet stocker.
Since an operator will not be standing at themachine and available to clear chips, chipaccumulation can be managed automatically if themachine has an automatic stocker wash andthrough fixture wash. In addition, it is important tohave the ability to run safely in manual or automode in case the robot is not available to load andunload parts.
It's also critical to have a seamless interface
between the robot and the machine functions. If
there is an issue that causes the process to stop in
the middle of cutting parts, you want to have theability to pick up where you left off through a part
restart routine. This restart routine needs tounderstand the conditions of the machine and theautomation to safely begin motion again withoutcausing a wreck. Another key factor in managing
the system is to have the ability to track the part
status in the machine to determine if it is a raw orfinished part. From a machine layout standpoint,
access points should be designed to avoid
interference with the automation. For example, thetool magazine door cannot be blocked byautomation guarding.

Designing the workholding should take into consideration
what is needed for smooth operation of the automation.
To assist the robot load, part loading guides and part
retention rollers can be employed. This will help direct thepart into the fixture and prevent it from falling away fromlocating pads when the robot lets go of the part. Loadverification through air part seat detect confirms the robot
correctly loaded the part and prevents a quality defect orcrash. Since an operator will not be at the load station toblow chips off locators, chip shedding features such as
sloped surfaces and the elimination of chip-catchingshelves can eliminate the buildup of chips. Anotherfeature that eliminates chips hanging up on the fixture isinternal hydraulic and coolant lines. Coolant nozzles
directed to clean off rest pads also help with chip buildup.
Also, to plan for the ability to manually load fixtures if
needed, Poke-Yoke features should be designed into thefixtures to prevent operators from misloading parts.
Some of the process related essentials for implementing
automation include:Ÿ Broken tool sensing
Ÿ Pallet seat confirmation
Ÿ Tool life monitoringŸ Tool length check macroŸ Safe start blocks

Makino has developed a Cell Controller with a userfriendly HMI graphical interface to minimize the need foran operator or maintenance technician to handle the robot
controller. This interface provides most of the key
operational data needed to understand the condition andstatus of the machines and system. Some of the functions
include:Ÿ Cell status overview
Ÿ Robot control
Ÿ Safety fence access control
Ÿ Gauge cycle counters
Ÿ Machine modes (Online, Runout, Offline)Ÿ Multiple part number management
Ÿ Robot homing routines
Ÿ Material handling control

The smooth and seamless interface between theautomation and the machines is what sets Makino
automation apart from integrators that piece together
discrete systems with handoffs. The robot interface
designed by Makino provides a standard set of interface
signals with these features:Ÿ Robot and manual load modesŸ Parameter selectable fixture control
Ÿ Part status tracking (Good/Reject/Gage)Ÿ Part restart support
Ÿ Automatic Gage flag for first tool used
Ÿ Customizable robot interface/fixture control
Ÿ Part type selection
Ÿ Auxiliary equipment control (conveyors, parts markers,part blow-off stations)Ÿ Robot work zone access control

What You Can Expect
Integration Services incorporates Makino machines
into your manufacturing environment. The
integration includes automated material
load/unload, customizing machine operations, andthird-party equipment. We provide full automationengineering services which includes cell controller
programming, robot reach services, robot end-ofarm tooling (EOAT) gripper design, robot
programming, conveyor designs, third-party
technical management and human management
interface (HMI) development. We've developed acell controller that can perform a series ofautomated functions, including displaying anoverview of the cell status, control robot start/stopand access to robot work area, gage cycle
counters, cell runout, part type selection and parttracking.

Every Makino Integration Solution includes an array ofservices that encompass each step of the project, fromstart to finish and beyond. To make this happen, Makino
has a team of professionals ready to work for you.
Project Management
With Makino Project Management, you have a single pointof contact throughout the project, one person you canalways rely on to answer your questions. Your designatedproject manager will oversee all third-party vendors,coordinate activities between all parties (Makino, vendors
and you), track and report the project's schedule and takecare of project changes.
Project Engineering
Project Engineering—which includes mechanical, controls
and software—is equally comprehensive. It includes:
Specification/design reviews
Drawing approvals
Mechanical engineering (Robot EOAT design, layout
design)Control engineering (Design and programming)
Third-party equipment runoffs
System runoff support at Makino and at your site
Installation and startup support
Final documentation

Applications Engineering
Applications engineering develops the production-readymachine process, tooling, and fixtures. With these metalcutting experts on the team, a fully qualified operation
meeting your Cpk and cycle time requirements is assured.
Site Supervision
Site Supervision includes on-site coordination of all theproject's installation activities.
Once again, you have a single point of communications
and responsibility on site. You also have an experienced
facilitator of manpower and scheduling.
Post-installation Support
A Makino Integration Services project continues long after
installation. Our Post-installation Support not only helps
make for a smooth transition into full production, but also
provides an on-going resource for training andtroubleshooting.

The Challenges ofIntegrating Automation
When integrating automation with machine tools
and other auxiliary equipment without a single
source provider, there are numerous challenges
that are commonly faced such as:Ÿ Multiple suppliers without a clear leader results in

no one being accountable for your overall
success
Ÿ Machining, part handling, and auxiliary equipment

operating as an island without proper
handshaking and communication across thesystem
Ÿ Takt time not balanced across the entire

operation resulting in inefficient operations and abottleneckŸ Each supplier working toward their own schedule

without coordination across all suppliers resulting
in delays at the customer's expense

The Makino DifferenceŸ When Makino is hired as your integrator, there isclear responsibility and accountability to makeyou successful.
Ÿ Makino provides single source solutions thatavoid the finger pointing between suppliersŸ Makino has extensive process and operational

experience that touches all aspects of theautomation and part processing
Ÿ Makino provides fast resolution of engineering

issues since the knowledge and control is under
one roofŸ Makino delivers a smooth-running, complete

system that results in lower manufacturing costs
across the project life cycle©Copyright Makino 2021