Haas Factory Tour 2020 - Haas Automation, Inc.

[Music] good morning guys we're here in oxnard california at the haas factory and today we're going to give you a tour of pretty much the whole facility so let's go in through the front entrance here and get started all right so this is the main entrance of course the lobby here now we've got racing memorabilia on each side from all of haas's race teams but we're not going to look at that right now double rooms over there we've got another video that covers that right now we're headed towards the machine shop we're here in building one of course we've got four buildings on campus here totaling over a million square feet under roof and we're gonna start in building one on the machine shop site as i just said right here actually we're on the other side this wall is rotary assembly we'll be coming back to that quite a bit later here in the video right now we're headed towards the machine shop side of building one and this is where we house a lot of our fms systems so building one machine shop site as you can see here we've got some rotary table bodies are surrounded by them actually hrt 1000 our largest rotary table trt rotary bodies and trunnion castings hrt310s 210s 160s runs the whole gambit but on this left side here this is kind of what we're going to focus on for right now all throughout the factory here we have a variety of different fms cells or flexible manufacturing systems is the long name for them right here we've got these machines tended by these uh pallet walls here and really this just signifies haas's investment in the right tool for the job we've been using large fms sales since before i started in 1997. so the concept and reasons are well-founded but we continue to make new investments in these systems because it's the right approach in some cases people ask why aren't you using haas machines throughout your entire factory and the simple answer is these large hmcs and pallet stackers are not the market segment that haas is building machines for but it is the right tool for the job in this case a high mix of parts at a medium volume makes these pallet stackers ideal the concept is simple really machine the right part at the right time here in the machine shop so that part is ready to put together on the assembly side of the factory when it's needed and keep these spindles turning as much as possible all right so we're leaving this uh the makino fms cells uh we've also got some japanese ones down that way round to the corner we're gonna head down this aisle here where we've got a whole line of ec 400s now these are our earlier version not the present one most of these machines were installed between 2012 and 2014 so six eight plus years old now this is kind of an example well this is completely an example of how hosta is the same style of machine as those fms systems we just looked at but in this case it's geared towards a medium-sized shop at a much more affordable price level but the idea here is that these horizontals are aimed at getting a high mixture of parts or maybe you're focused on one specific part all of these cells are mostly concentrate on one or two parts or a few parts where we're doing very high volumes but you can see when you attach a pallet pool like this to one of these hmcs you've got a lot of fixture positions and the idea is with the pallet pool loading and the pallet changer loading those pallets in and out of the machine continuously your spend along time is maximized you can see right here we're making motor housings for our machines just one example of all the different parts we make on this line here all right so we're right next door to where we just looked at those ec 400s now you can see we've got this line of bmc 1000s these replaced older models just recently but the idea is the same here just from much larger parts each one of these machines has 10 pallets and you can see we've got a variety of different castings we've got saddles bases just a huge part mix but on these huge thousand millimeter pallets the focus is large parts of course all right moving on from those fms cells this is uh one of our two cylindrical grind areas we've got kind of a variety of robot loaded and manually loaded cylindrical grinders and you can see right here we've got a robot tending uh this studer grinder they do spindle shafts of course all the different kinds of shafts transmission shafts as you can see here we've got a large variety of different output shafts anyway let's let's head around here more cylindrical grinders and then right over right past these machines here are our gear hoppers we'll take a look at that in a minute but let's head this way over here we have this giant this is our newest gear hopper here this giant modal gear hopper and we bought this primarily to focus on the largest rotary gear sets that we make now you peek in here right now this is an hrt310 gear if you want to take a look in there but really this is focused on hrt 600 800 and 1000 rotary table gears so really large gear sets anyway huge gear hopper now over here on this side we've got really the bread and the butter of uh the gear hoppers here these focus on hrt 160 210 310 and up uh gear sets and the thing here is these are you know we've got millions of dollars of machinery here but it's not just the machines you can't put these into your shop and expect to be making high precision gears that fit perfectly and yield really good rotary accuracy you know a week later you also have to have the the crew of professionals that have all the wisdom and the knowledge to make those machines run correctly and that's what we've got here all right this is our inspection room here considerably quieter than the rest of the factory um this is just another example of haas's commitment to quality we've got a huge variety of measuring tools in here but probably you'd say the star of the show are all the different cmm's we've got here this largest one is three by one and a half by one and a half meters we use this for measuring our largest castings with a variety of other measuring tools we do something like fifteen thousand tools that we calibrate every year super accurate measurements are the norm with this wenzel wgt500 with air bearings on all axes a granite base plating guides hydraulic rotary table and high resolution scales this unit has accuracies in the micron range as we use it for daily inspection of worm gears and shafts and other gear and spline forms using this scanner we can compare a live scan to the cab model of the part accuracy is within two thousand five meters and is even more accurate over shorter distances this is a great way to evaluate complex castings prior to machining and the results of these scans can even help our setup machinists decide how to best fixture and probe a new casting anyway all kinds of cool stuff in here um well let's head this way for now all right so here we're sitting in front of these giant mpcs focused of course on huge parts we've got umc bases behind us a big sd 50 base here anyway you can see that these are pallet fed machines as well you can load your part here while you have another batch of parts running on the machine so it's kind of the same idea as the other fms systems just for much more massive parts all right we're just leaving the machine shop side of building one so we've just done one half of building one we got a long way to go but out here it's kind of an example of you know just the basic infrastructure of the factory you can see here we've got compressors and we're looking at about 650 horsepower something like 2700 cfm of airflow that's a quite a bit more than your standard shop um past that we've got our cool recycling area and on average we're recycling about 3 000 gallons of coolant every month we evaporate the water and then recycle all the used oil of course um also here you can see our propane area this is where we have all the propane tanks to fill up the 200 or more forklifts we have driving all over this place um and then you can see these castings here these anything that's marked with red like these are our first article castings coming in from inspection from our casting vendors all over the country and all over the world so let's keep moving we're going to go head on over to building two to look at some more of our machine shop all right so we just walked into building two and this is of course the machine shop side of building tube in fact all of building two is pretty much machine shop now behind us are of course more fms cells and really it's the same story we use these to build a high mix of different parts on this side these machines are mostly concentrating on aluminum these days but the idea here is that overall in this machine shop we have about 60 machines dedicated in fms sales and over a thousand pallets so i don't know if it's the biggest in the world or in this country but it's huge to say the least all right so we've left the area with the fms systems now we're back over in another area devoted to really large machines um this right here this bb3 from 2005 i think it is you can see it's still being used right now we've got an ec 1600 table sitting on here they've got a rotary control box hooked up to it not sure what they're doing but they do kind of one-off stuff on that machine from time to time and then right here we have more of the older mpc double column machines focused of course on the largest castings these have been here for a long time but still chugging away and then on this side we've got these akuma mcrs this is just essentially a newer a little bit more sophisticated quicker version of the same thing all of these machines of course are pallet fed so you've got a part waiting to go you've got your part being machined and then as soon as it's done it moves out of the way and you load another one so you're maximizing spend a long time all right this is going to be the last fms that we'll look at today this here is one of the largest fms systems in the entire world based on the number of load stations and the linear number of pallets involved here we've got a really large mix of parts you can see all the castings up there on the pallet wall lace spindle heads lathe gearbox housings tail stock housings just a really wide variety of parts all made basically just in time for the production line so now we're entering an area that's filled completely with haas machines as you can see on this side we've got one of our robot cells this cell is dedicated to building columns just vf1 vf2 columns very high volume in here we've got four of these cells with e6 1600s tend to buy robots we're building columns over here tables and saddles over here saddles over here saddles there as well so these cells are all dedicated to making one or two parts at very high volumes these are machines responsible for keeping our small and medium vf casting lines running continuously at really high volumes so now let's head on to this side so all these cells use 260 ec 1600s manned by a robot in the middle on this side we have a different configuration this is typical of our other kind of robot cell here we've got we're usually looking at two leis and a mill tended by a robot in the middle these are mostly focused of course on making round parts spindle shafts a variety of round other flat parts so this cell here is an example of one that's dedicated to just one part these are 40 taper spill housings of course we go through a whole bunch of these every day probably upwards of 50 40 50 of these a day right now so this cell is dedicated just to making those now let's head back this way we're going to take a look at what we call our batch production area and that's just a big group of haas machines dedicated to making a whole variety of different parts mostly on the smallest mostly smaller parts turned and milled parts let's head over here so this is what we call the batch production area this is really the area of our shop that's the closest to a regular drop shop we've got a variety of mills and lays this particular area is a little bit near and dear to my heart because back in another lifetime here when i was a manufacturing engineer these four actually most of these machines here but these particular super speed vf2s a little bit older these are all around 2008 we put these into place and at that point i was the guy that was responsible for doing the factory floor layout making sure these machines came into place and older ones got moved out in their place but you can see here we've got a testament to how long these things run these have all been here for 11 12 years or so running non-stop so let's head back out of here and just like a job shop this area is really focused on doing shorter runs of parts um stuff that the line needs right now now we're going to head from here and we're actually finally leave the machine shot and we're gonna head towards assembly [Music] okay so on the left here we have electrical assembly and we've pretty much divided this area up into two different distinct areas this is the control cabinet assembly on this side and then over the wall we've got electrical sub assemblies we put together the control cabinet in a 20-step assembly process with nine minutes of assembly time allotted per station we start with the chassis plate of course and then add the major components like the transformer the vector drive i o and main combos and the amplifiers for each axis at the same time in the electrical subassembly area we're building all of those major components and a host of other supporting ones that go into the control cabinet each control is built and serialized to match a specific machine sales order it is configured for the options selected and to match the electrical requirements for the part of the world it's shipping to it meets up with that same machine about a week after it's built on the machine assembly line okay so we're leaving electrical assembly now we're getting into the actual assembly where we put the machines together on this side we've got large vmcs and on this side we've got umc assembly we call these the cast assembly areas this is where we put the foundation of the machine together if you look at this uh vmc for example right here you can see we've got the base uh saddle table column spindle head and we put these machines together all quite in in quite a similar way really it's what we call the stack axis method it's pretty simple really um we start with a base on the ground lay down the linear guides then the saddle then the table typically we build the column offline separately we'll put down the linear guides and ball screws there and then we'll attach the spindle head to that and then we'll lift that column assembly and put it onto the base and there you've got your entire basic machine assembly ready to go then from that from that point it leaves this casting assembly area here and we move on to what we call the final area so this is the umc final area um a few years ago was only the umc 750 we've got one of those right here of course but these days we've got the smaller brother and the larger brother to the 750 um that's probably umc 500 right here see there's a little bit smaller small footprint moving from that to the biggest one we're offering now this is the brand new umc 1500 duo in this case an ss version here we've got the trunnion rotary table and a vf2 table so you've got two complete different work envelopes you can take care of lots of possibilities here let's go across the aisle now we've got over on this side we've got ss so the super speed big brother to the 750 and the 500 right here so of course when we come to the final line uh the idea here is after the casting assembly is done you're in the final line we take care of the geometry of the machine aligning all the axes then we put on the sheet metal install the control and then do all of the testing that goes into making sure the machine is ready to go amongst the many tests each machine sees before leaving the area it will have gone through a final geometric alignment check checks like squareness of the z-axis relative to the x-y plane and spindle center line to z-axis parallelism and then a laser rotary accuracy check this renaissance xl80 laser interferometer allows us to measure rotary rotational accuracy with precision to plus or minus one arc second this is followed up with a ball bar test to check proper alignment and motion of the axis and of course we perform the test cut to check actual cutting performance okay so leaving the umc area now we're entering where we build all of our ec machines this is our brand new ec 550 taper just released this i believe is the first one right beside it here is one of our ec400s pretty much in the same stage as those other machines we saw here we we built these machines all in one spot we don't have a casting area in the final area because the production levels are lower and since they're even larger we typically like to just leave them in one spot and bring the sheet metal to them as we assemble them now let's walk through this is where we build our gr gantry routers and our gm gantry mills you can see this right here gm25ax got this five axis hit on here uh this has got the extended z travel super capable machine for doing really large five axis parts so now let's leave this gr area and we're going to walk straight back over here so now we're in large vmc final area and this machine is an example of one that's in the middle of getting the geometry checked it's kind of the same for all these different lines you get this machine out of the casting area and you're going to line up all the geometry of the different axes make sure everything's square perpendicular and then from there you're going to start installing the sheet metal and then it goes through the whole plethora of different tests leading up to the final test cut okay we're gonna head back into the machine shop one more time to take a look at a couple more cool spots so these cells here are an example of how we do kind of medium volume medium-sized castings and keep the spindles turning as much as possible here we've married up we've got a whole bunch like seven of these cells and typically it's a vs3 married up to one of these mitocho palette changers so here's the pallet changer and up here of course is where the machining is happening so we've kind of run two different things here medium sized lathe bases small lathe bases and then on some of the other cells we run medium and small uh vmc castings so let's go walk down this aisle way here so we used to have we used to we've been running these vs3 cells for more easily more than a decade here but more recently we've teamed those up with these mitocho palette changers and it's the same idea as we see on even the fms systems and any of the ec 400s you're carrying multiple parts so that you can keep the spindle turning the entire time you've got one part staged one part being machined so you keep that spindle turning let's go through here we can see more of these pallet changers here we are where we're getting ready to load these small vf bases onto here so that that machine will run those got one more thing i want to show you before we before we leave this building here we have two cells dedicated to making just the uh the sidemount tool changer cams and we used to have ec 630s were that were custom kind of custom modified making these castings so quite a sophisticated machine and these are sophisticated but it's kind of a more simplistic approach if i come in here you can see this is just a vf3 with a customized trt210 rotary table on here it's just essentially an offset platter mounting and these cells are dedicated to cranking these cams out all day long every day we've got another one right over here and that's just because we make a lot of tool changers every day let's head this way we're going to take a quick walk through the casting yard here okay so we're entering the casting yard here as we call it um this is a favorite uh for when we're doing real live tours of course now this is where we hold the bulk of our castings before they get machined as you can see we've got castings on every side large vmc columns over there small medium bases here let's keep walking this way more medium base castings here um we're looking at around 7 million pounds a month right now 350 000 some odd pounds uh of cast iron machined every day here we get our castings from pretty much all over the world usa canada china thailand india poland and all of those castings go through the same rigorous inspection here they all have to meet the same specifications no matter where they're coming from so as long as they meet the specifications we're good to go here are some you know some more similar casting we have umc castings back there umc 750 castings here we have ec 400 base um runs the gamut really and what's crazy is that all these castings here this is about a one month supply we'll turn all of these castings or pretty much all these castings over every month so it's a huge amount of cast iron we're talking about let's keep walking through here and we're going to head to building four our inventory building and uh take it take a look at the huge pallet racks and the narrow aisle equipment over there um let's head this way so this is building four um this building houses all the inventory for the entire factory um so in a second we're gonna see all the all the inventory racks but right here you can see we're actually doing assembly work here this particular line is dedicated to small and medium enclosure assembly for the vmc line it's our highest volume line so we put them together here roll the motor to building one just a more efficient way to put together these large enclosures let's keep going this way now we've got kind of a mix of regular width aisles here and then as we see in a set as we'll see in a second we also have narrow aisle equipment just to get more density of course you want to store as many parts as possible we store literally tons of sheet metal here sheet metal is really the biggest space hogs if you will so we store a bunch of it here um in front of us here is where all the incoming or inventory is handled we we typically fill and then clear this area three times a day we've got some nearly 700 vendors worldwide so all of that inventory is coming in onto this dock and then disseminated into these pallet racks every day so in this building we've got 34 foot high ceilings uh 10 feet higher than than any of the other buildings in the complex we have precision flat floors with guidelines on the floor for use by the narrow aisle for trucks we were putting this building up we used one and a half million pounds of pallet racking and that gave us seventeen thousand pallet spaces we have more than twenty thousand different part numbers in this area and over fifty million dollars in inventory typically we're looking at about one a half million dollars a day coming in from our various suppliers all over the world as i said before almost we're somewhere around 675 suppliers worldwide we're looking at typical inventory levels of 10 000 ball screws and 30 000 linear guides at any time we uh stock components from thk nsk bosch ena steinmeier and skf our total consumption of these two critical parts is around 33 000 ball screws and about 87 000 linear guides every year so this is the service parts shipping area here in the factory this is kind of on one side of building four here you can see these are all orders going out to our dealers um we hold about 10 million dollars in stock here and that's in addition to the 75 million or so dollars that are held at all the hfo consignment stocks around the whole world the idea is for uh dealers to ship service parts from their warehouses or to have those actually in the service vans that are going to the customer shops but whenever that isn't the case we're shipping those parts next day from here and typically we're maintaining a 99 same day shipment if you go to our service webpage and you page down a little bit you'll see that we actually post what we're maintaining service percentage shipment wise every day and typically we're above 99 pretty amazing that means that if a customer needs a part they're gonna get it as soon as possible so we're headed back towards building one we're going to end up finishing up on the building one assembly side of things just left building four but i just wanted to mention here this is what we call our freight consolidation area most of these machines are headed overseas um but sometimes we even gather together larger shipments they're headed to the us but the idea here is large groups of machines all headed to the same hfo we want to group together in one shipment so we've got machines staged here going all over the world who knows maybe one of these machines is headed towards your region now but for now let's head back to building one we're going to take a look at assembly all right now we're back at the very front of building one actually on the other side of the wall where we first walked in at the beginning of this tour now this is the rotary assembly department rotary tables and indexers of course is where haas got its start nowadays we're surrounded by a lot more than just the basic indexes and rotary tables haas has been making programmable indexers and rotary tables even longer than we've been making cnc mills and turning centers maybe you'd think that years ago we would have been content to sit back as the market leader in rotaries and sell the same products we developed 10 years ago but not at haas we always keep trying new things we were making five axis trunnion cell rotaries as far back as 1988 and we've never stopped developing new ways to make fourth and fifth access machining more accessible and more productive from our tiny hrt 100 to the mammoth hrt 1000 rotary tables and 5-axis options from the trt-70 all the way to our just developed tr-500s we're always looking for ways to help you put more axes to work on your milling machine all right so we're coming from rotary assembly into vmc assembly and that's probably fitting because that's basically the progression that haas followed from rotary tables to vertical machining centers so this is the cast assembly area and this is actually this assembly line what we call a flow line we just put into place recently really this is just a more efficient way and maybe maybe a little more consistent way to put together uh vmc columns in this case small columns this is our highest volume uh column assembly that we make here you can see that this is kitted ready to go so that once it's assembled here it's taken over to this side this is where we do the the entire uh stacked axis method we were talking about earlier we place the base on the ground add the linear guides and ball screws install the saddle and table and then we take that column assembly that we built over here lift it with a crane drop it onto the top of this guy here and you essentially have the bare bones in the machine then we take this finished bare bones machine here we take it across the aisle and we head into what we call final assembly like we saw on the umc line here in vmc final assembly we conduct numerous tests to ensure each machine is ready to provide accurate dependable results day after day geometry tests like t-slot parallelism saddle and column squareness and spindle sweep verify that the machine is in correct alignment then we move to dynamic checks like ball bar and spindle vibration tests to verify that the machine does what it's supposed to while in motion and in the cut all of these culminate in the test cut we run on every machine before it shifts we're going to leave the mc assembly and head towards lathe assembly now we're entering the lathe assembly area as you can see right here we have some assemblies that are getting ready to be put on this line wedge assembly here with the turret attached all ready to go over on this side we have spindle heads ready to go on the line another wedge assembly now over to my right hand side here this is where we put together the small lace sd20s and then over on my left hand side this is where we put together the st-30s now similar to the mill line we have a cast area and a final assembly area this is the cast assembly area kind of the same idea here you place the base on the ground put down the linear guides and ball screws and then you start adding all the all the large sub-assemblies in this case oh let's yeah let's get back to this one here now you see here we have a base casting where no assembly work has been done yet just getting ready they'll level this out then they're ready to put on the ball screws and linear guides right here we have an assembly that's progressed along a little bit farther this is the bare bones spindle head right here here's our wedge assembly and the turret tail stock these are kind of all the main components that need to be on this lathe to turn into a functional machine ball screws linear guides everything has been installed from this point they're going to attach the control and then they'll start building the sheet metal around it after they make sure everything geometrically is moving correctly let's go from here down to the final line so here we are on the lathe final line this of course is the small lathe sd-20s 25s this sd25 is well looks like it's almost ready for shipment it'll be completely final packed up in a minute here um it's running the last series of tests it's kind of exercising control and the axis motion once again here i've beginning to sound like a broken record but the idea is the same in lathe final as we saw on the mill lines test the machine thoroughly so we know it'll perform as expected when it's in your shot again we'll double check geometric alignment with tests like spindle axis to z-axis parallelism and tail stock alignment moving on to the dynamic tests we'll check spindle vibration on these much larger spindles just like we do for the mills and yes lathes get ball bar tests too x to z axis y to z axis we need to ensure the axes get to the correct position and do it smoothly throughout the full range of motion and of course we test cut our turning centers just like we do our vmcs then we install whatever options are attached to that order test those and the machine's ready to ship it's going to go from here out to our shipping area let's take one more walk and finish up in the shipping area all right here we are at long last at the back end of building one this is the shipping area here at the factory and this is of course where all those machines and all those different assembly lines end up and they get packed for shipment to an hfo near you or a machine shop near you we'd like to thank you for joining us on this uh whirlwind tour of the factory here and we really hope that the next time you're in town you can join us here for a real live tour thanks for joining us and we'll see you next time [Music] you

Channel: Haas Automation, Inc.

Views: 101,935

Keywords: CNC machine tools, CNC machining, Gene Haas, Haas Automation, Haas CNC, CNC, Haas, haascnc, machining, manufacturing, cnc machines, cnc mill, milling machine, cnc machine, cnc milling machine, machine tools, lathes, cnc machining, rotary table, cnc machinery, cnc machine tool, boring bar, cnc machining center, cnc cutting machine, haas factory tour 2020, haas automation factory tour, haas automation factory tour andrew harnett, andrew harnett haas automation

Id: gjRkMaG4CCM

Length: 34min 10sec (2050 seconds)

Published: Tue Dec 08 2020