Ensuring repeatability and process standardization at Fairbanks Morse

When Fairbanks Morse Engine installed a robotic welding cell at its Beloit, Wis., headquarters, the goal was to increase output of the massive marine propulsion systems it manufactures. So when Robotics Engineer Steve Hill found that productivity at the 125-year-old company had plateaued, he needed to identify the challenges that were throttling their automation speed.

“What challenges were we facing?” asked Hill. “I think the better question to ask is what weren’t we facing? We have a very diverse mix of parts. Repeatability and process standardization were huge challenges, because many of our fabrication methods are based on tribal knowledge. We also had a lot of outdated prints and fabrication methodologies.”

The net effect was a robotic welding cell starving for work while waiting for subassemblies to be tack welded and for larger weldments to be fixtured up.

The answer, Hill knew, had to be modular. He had used Bluco modular fixturing at a previous facility, so he knew it was suited to their needs.

“Bluco is synonymous with modular. Plus, I knew there would be engineering support with it, so it was a no-brainer.”

Making the Case for Modular

Hill started by uploading CAD files to Bluco’s secure website. He then collaborated with Bluco Sales Engineer Josh Hill.

“I explained how I needed to pitch it to management,” said Steve Hill. “He basically helped me build the case for it. Josh took the time to come out for a visit to get a feel for the environment here. Then he designed what our leadership needed to see. He didn’t just hand me a catalogue like a competitor did. The interpersonal interaction between Josh and our team, that was the catalyst that got this put out onto the shop floor.”

Time Savings, Increased Accuracy

The Bluco installation consisted of five tables with rolling legs atop 12 m of rail and featured a specialized component kit; the full setup can fixture nine different parts. It also included a batch of custom digital templates made by Bluco specifically for Fairbanks Morse. Hill said all six of his operators were proficient with the entire system within two weeks.

On top of that, Fairbanks immediately saw massive time savings. “We had an 18-ft.-long oil pan that used to take over a month from start to finish. Now it takes two days. That’s astronomical for us.”

How did they save all that time? “The guys had to lay it out before, using chalk lines and tape measures, and only two individuals in the entire shop knew how to build them. The guys that started off building these weren’t even the operators that knew how to build them from tribal knowledge. These guys were finish welders, not setup welders, and they built the part in a third of the time that the seasoned operators were able to do it. And it was dimensionally correct. That’s what is absolutely mind-blowing to everyone here. I can’t even really describe it other than to say it blew everyone away, including the leadership here at Fairbanks,” said Hill.

The Fairbanks team experiments with Bluco toggle clamps that generate up to 400 lbs. of force

Custom Templates

The modular installation went beyond just new hardware — it also included custom design services that solved some of Fairbanks’ toughest fixturing challenges.

“We do have some specialized parts that are extremely difficult to build, but that’s where Bluco engineers made the difference,” said Hill. “They came up with custom templates to build some of the most challenging parts we have.”

Because the Fairbanks team can access these digital fixture templates from a workstation on the shop floor, productivity soared.

“We didn’t just get a rail system; we got an entirely new process. In this one purchase, we were able to have an 80 per cent developed SOP right out of the gate, just by going to this digital design,” said Hill.

Ensured Repeatability

While time savings and ease of use impressed the Fairbanks team, the ROI of the system has also turned heads. “We’ve been able to have a full return on investment in six months,” said Hill.

Looking back, Hill sees the challenge they overcame with complete clarity. “We purchased a large automation system with a high expectation of increased throughput. But we didn’t have repeatability to lead up to the automation. You have to have that. The Bluco solution provided that. It stabilized everything and made the process repeatable.”

Fairbanks Morse Engine, www.fairbanksmorse.com

Bluco, bluco.com

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