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Modulo

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Modulo 5

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Modulo HP

The new high productivity modulo is the solution for high volume production needsDiscover

Relief valves for the automotive industry

Production objective: 1.8 million pieces per year. With the 4 modulo5 units, Fleury guaranteed to produce 1’833’499 pieces in one year.
Discover how Fleury is able to achieve this challenge.

Case study Automotive industry

PRODUCTIVITY MANAGEMENT

In the world of excellence, everything begins with clarity

Fleury offers unique, quality services. But we are more than a service provider – we are your partner. As such, we bring all our skills to the table and foster transparency from our very first contact with you. Before going into production, our experts provide you with a clear analysis based on rigorous calculations for the most accurate strategy and timelines possible. This ensures you have total control over your schedule, productivity and costs.
Here’s how we did it for a major player in the automotive industry.

  • ✓ Introduction
  • Explanation of the case study
  • ✓ Conclusion
  • ✓ Auxiliaries

The FLEURY approach

The request

A client active in the automotive industry contacted us for the production of relief valves, a complex part that must be machined on several sides. The production goal was set to 1.8 million pieces per year. With a sample part that the client had provided with the initial request, our specialists carried out an in-depth analysis. To be able to meet the client’s request fully and in total transparency, we determined with great precision the model and number of machines required, as well as the space required in the plant to achieve the production target.

Model and machine availability

On the basis of the operations to be performed on the part, we first determined that the Modulo 5 was the best-suited type of machine. To provide a realistic output estimate, we then calculated the probable availability of a Modulo 5 over a one-year period. On principle, we choose to use a particularly pessimistic projected availability rate, counting four weeks of machine shutdown. The result is then expressed in seconds to match the machining cycles per part.

We came to a total of 24,675,840 seconds per year, or 85% of availability for one machine.
Experience shows a 98% accuracy rate in such a projection.

Production time per part and per machining unit

To complete the work required on time, the ideal milling unit was a 6-compartment fastening pallet. This then brought us to a total of 323 secs. per 6-piece loader, all operations included – in other words, 53.83 secs. per workpiece and per machining unit.

Final results

All we then needed to do was to divide the time of availability by the manufacturing time per part. We came to a result of 458,375 workpieces per year and per machining unit. With our target set at 1,800,000 pieces per year, we were able to conclude that 3.5 machining units would be required. With 2 units on each Modulo 5 machine, we therefore showed our client that two machines would be needed to reach output targets. With the 4 units (2 per machine), our client was guaranteed a yearly production of 1,833,499 parts.

No room for chance

Upon conclusion of our analysis, the client was able to get a detailed estimate down to the cent, set a precise schedule to the second, and even determine the space required on the factory floor, right down to the centimetre. Thanks to our rigorous calculations, our client was able to order the necessary machines while remaining in full control of all parameters of the operation. Once received, all our client had to do was turn the machines on: they were already programmed. From start to finish, our client enjoyed peace of mind, knowing not only that production targets would be met, but exactly how. We had certainly successfully fulfilled our mission.

The solution of Fleury for this case study

Modulo 5

  • 5 axis
  • Oil machining
  • Parallelepiped parts

The modular5-axis linear transfer machine for fully automated production.

Our new modulo5 is a 5-axis linear transfer machine able to combine machining processes such as milling, turning, boring and grinding in a single operation and to completely machine the workpiece on 6 sides. Each manufacturing unit is equipped with two 5-axis processing units and has its own control system, as well as automated pallet handling. Since modulo5 is fully automated, production can continue around the clock, 7 days a week.

Due to its high power density (13kW per spindle) and for its small foot print, modulo5 offers an extremely competitive solution for the production of workpieces from small batches to mass production.

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