After conducting extensive research and by visiting a number of EDM equipment manufacturers, we decided to go with the newly designed and introduced Mitsubishi model EA12V and System 3R WorkMaster Robot in an automated cell to address its challenges. The company worked closely with MC Machinery Systems (Wood Dale, IL)—who was the first company to introduce automation in the company’s thought process.

we were impressed by their role more as “project consultants” than “salespeople”—and determined this was the best fit for their business.

Initially we approached suppliers for a quote on a new sinker EDM and two new automatic tool changers,Together, we strategized and purchased the WorkMaster Robot simply for changing out the electrodes from our two sinkers, our existing Mitsubishi EA8, and our new EA12V.

Then, we started by standardizing and automating different parts of our mold building process to increase our efficiencies. Electrode holders were standardized as much as possible to incorporate a similar design for commonality.Then, once we purchased the equipment we applied some of our own unique manufacturing processes,

We set up a customized mold build tracking system—and combined with the automatic cell—our throughput really began to improve. There are components of the cell that are common to all systems (the robot, fixtures, etc.), but the real trick is to try and get them all to ‘communicate’ when you’ve got the robot talking to both of your sinker EDMs.

It also is challenging to get everything set just right so you can achieve the best in unattended productivity. The keys to success are the right equipment, the right people and the right processes. You have to have all three; it’s not simply about buying the equipment. We’re fortunate to have a very flexible and highly talented team, and we really challenged each other to find the very best solutions, not just any solution.

In time, as the company’s processes are evolving, they are adapting the robot to change out workpieces from their EA12V, and are working to do the same with their Makino S-56. As more time passes, we’ll be incorporating a high-speed graphite mill into the cell. MC Machinery provided us with a solutions-oriented plan that evolved into what we are doing today,We are the very first company in North America to invest in this newly designed EA12V.

Wilson adds that while the equipment manufacturers and suppliers can be extremely helpful in teaching about what the equipment can do, he found Omega employees needed to do a lot of homework, research and experimentation on their own.Each company is unique in the way they go about designing and building molds, so you really have to find your own way to a certain extent. You need to spend a lot of time and resources to make the equipment function in your specific application. It’s important to analyze your own business and how you want to apply the equipment to your own business—and how it fits within your strategy.