OMATIVE s Adaptive Control & Monitoring at HYUNDAI-KIA (various facilities in Korea)

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1 OMATIVE s Adaptive Control & Monitoring at HYUNDAI-KIA (various facilities in Korea) Industry: Automotive Hyundai was established in 1946 and quickly became the largest corporation in South Korea. Kia, which started off by manufacturing bicycles before turning to motorcycles and trucks and later cars, was founded in Hyundai and Kia merged in 1998 currently have an approximately 80% share of the automobile market in their native Korea and an approximately 9% share of the worldwide market. Globally, they are the fifth largest auto-maker. Hyundai-Kia has factories around the globe, in North America, China, Europe, Russia, the Middle East and South East Asia. OMATIVE systems were implemented extensively in production at those locations. This case study reports on OMATIVE s Adaptive Control & Monitoring (ACM) performance for different machining operations at Hyundai-Kia factories involved in the manufacture of engines (crankshafts, cylinder blocks, etc.) and transmissions. Crankshaft production Milling Ulsan, Korea plant Objective: Tool life extension Crankshaft milling with the ACM 1

2 Real-time load and feed rate variations recorded in Ulsan shows that the crankshaft milling operation has sharp variations in material removal rate. During air cutting, the ACM limits the feed to 100% of the programmed feed. Upon material impact, the ACM reduces the feed to 50-60% in order to protect tools from breakage. During heavy cutting and high tool wear conditions, the ACM reduces feed to 70-80% of the programmed feed in order to protect the tool from overloading. The reported results from the Ulsan facilities show elimination of tool breakage and stabilization of the manufacturing process. Tool life extension - up to 63% Tooling cost reduced - up to 38% Milling Hwaseong plant (crankshaft) In the KIA Hwaseong plant, OMATIVE s ACM system was implemented on a Komatsu machine for crankshaft milling. This resulted in extended tool life of 150%. According to KIA s report, tool performance increased from production of 600 parts to 900 parts before insert changes. Moreover, tool life was found to be stable. 2

3 HMC Alabama, USA plant (crankshaft) KMC Crankshaft Miller OP40-A/B machines ACM main screens on a Komatsu External Miller ACM cycle time saving (14%) on KMC Crankshaft Miller OP40-A/B machines 3

4 Screens from OMATIVE-Pro network monitoring of (two) KMC Crankshaft Miller OP40-A/B machines Turning operations - KIA Hwaseong plant (crankshaft) Crankshaft turning operations on Hwacheon machines with ACM implemented screen shows variations in speed, feed and power that take place with ACM implemented 4

5 Gun drilling Ulsan, Korea plant (crankshaft) Objective: Tool life extension Cutting characteristic variations were recorded for the ACM used on the angled oil hole gun-drilling machines at the Hyundai facility in Ulsan. The graph below shows the drilling operation at the beginning of the gun drill s life, when it was new and sharp. As can be seen, the load variation pattern is relatively smooth and the ACM reduced the feed only once over the whole drilling cycle. Gun Drilling Adaptive Feed Control (New Tool) Gun Drilling Adaptive Feed Control (Dull Tool) In comparing the two graphs, it can be seen that with the ACM, drilling feed rates with a worn tool are generally lower than that with a new tool. The ACM maintains the optimal cutting load pattern during the tool s life cycle. When the tool is new (sharp) the cutting load is lower resulting in a higher feed rate. When the tool is worn (dull), the cutting load is higher and the ACM reduces the feed rate in order to maintain the cutting load within the permissible level. 5

6 Sample tool life extension in crankshaft milling and gun drilling As is evident from the table above, using the ACM leads to a much greater number of parts being produced in crankshaft production operations. Not only are tooling costs reduced but the production processes are also smoother as they do not need to be disrupted in order to change broken tools. Turning operations KIA Slovakia plant (crankshaft) Objective: Tool breakage protection and tool life extension KIA Motors Slovakia plant U Model crankshaft turning operations on Hwacheon machines. Screen shows feed, speed and power variations for the machine with ACM in feed control mode and used for tool breakage protection and tool life extension. 6

7 Sample time savings in crankshaft external milling Komatsu 2-Spindle; Fanuc 18M/Hard Steel Seconds Cycle Time without ACM = 56.5 sec. Tool Diameter = 300mm, Teeth = 40 RPM = 247, Feed = 600mm/min Cycle Time with ACM = 47.0 sec Cycle Time saved: 16.8% Cylinder block production In machining of each cylinder block, drilling tools with varying diameters are involved. The ACM was applied for drilling and boring operations as shown below. Milling and drilling at Ulsan, Korea plant (cylinder block) Objective: Time savings OMATIVE ACMs were implemented on 12 Horkos machines involved in cylinder block manufacturing. Data for cylinder block production: Savings from 9% to 23% were recorded. Tools for which savings is not shown were those that were monitored to avoid breakage 7

8 Milling and drilling at Ulsan, Korea plant (cylinder block) Objective: Time savings Hyundai DC10-50M; Fanuc 18i /Cast Iron 45 Cutting Time Comparisons With OptiMil Without OptiMil Seconds Drill Drill Drill Drill Drill Drill RPM=4400 RPM=4400 RPM=1800 RPM=1600 RPM=4000 RPM=3380 Feed=570 Feed=570 Feed=530 Feed=530 Feed=880 Feed=864mm/min Dia=8 Dia=8 Dia=18.2 Dia=16.2 Dia=10 Dia=10.5mm Overall time savings = 18.5% Upper valve body production Enshu Machine, (Aluminum) Objective: Time savings Upper Valve Body Operation OP-10 OP-20 OP-30 Customer Expected Cycle Time (seconds) Actual Without ACM Actual With ACM A B C D A B C A B The table above shows that for operations OP-10 and OP-20, there was a 2.8% time savings, while for OP-30, the savings was 5%. 8

9 Transmission production Gear hobbing Seosan, Korea plant Objective: Tool life extension and tool breakage protection (Report below submitted by Hyundai Power Tech) 3 - Transmission part Transmission p art 4 - sum - Tool life - Improvement I - After improvement C/TIME - Improvement I - After improvement 72후 72후 52후 52후 - Tool life : 10% - Improvement objective: 10% : 80% - Improvement: 80% - Hobbing tooth - Improvement I - After improvement - no more than - no more than The table above was submitted by Hyundai Power Tech, based on their own data and measurements. It shows that using the ACM system to machine transmission part 3, they produced 1500 parts without changing the hobbing tool, as compared to 800 parts without the ACM. For transmission part 4, they produced 1200 parts using the ACM, as compared to 640 parts without ACM. The table also notes that machining cycle time remained the same whether they used ACM or not and that after increasing part production by 80%, the tool was not more worn than usual (when producing fewer parts). 9

10 Transmission planet carrier Milling, drilling and boring Seosan plant Objective: Time savings IN SUMMARY In many of their factories, HYUNDAI-KIA optimize their manufacturing operations with OMATIVE s systems, giving them an edge over their competitors through shorter machining cycle times and other financial advantages of cutting with OMATIVE, such as extended tool life and higher quality parts and surfaces, attained through optimized machining and ensuring dull or broken tools are not used. 10