![\"CNC-Bearbeitungszentrum](\"https:\/\/sw-machines.com\/wp-content\/uploads\/2024\/09\/SW_Tecomet_BAW02-22-Medizintechnick-2.png\" "\\"SW_Tecomet_BAW02-22-Medizintechnick-2\\"")
<\/span><\/div><\/div><\/div><\/div><\/div>Multiple part sizes and multiple configurations, high quality requirements with tight tolerances, complex production processes, and high volumes that must be manufactured as quickly and efficiently as possible: poly manufacturing for the orthopedics industry faces several challenges. The Irish expert Tecomet relies on two-spindle machining from Schw\u00e4bische Werkzeugmaschinen GmbH (SW), which helps to increase their knee implant production per operator and achieve an overall equipment efficiency increase.<\/strong><\/p>\n<\/div> Tecomet is a leading metal and materials innovator and contract manufacturer for medical device markets. The site in Cork, Ireland, serves as the Center of Excellence for Medical Device Poly Manufacturing. Here at Cork, over 100 employees work on solutions for the orthopedics industry, producing large volumes of metal and polyethylene parts for medical implants. For knee implants alone, several hundred tibial inserts are manufactured weekly and around the clock. In this tightly scheduled manufacturing process, low downtimes and overall equipment efficiency are crucial to meet customers demand and quality requirements. \u201cUp until 2022, we only ever used single-spindle machining centers in our tibial poly insert production line,\u201d Peter Grehan, Engineering Manager at Tecomet, says. \u201cWhile these machines work well, we knew there were faster and more efficient machines out there. \u00a0The single spindle \/ single table machines require frequent manual interventions switching between Op1 and Op2 fixturing. We knew we needed to streamline and increase our capacity with limited floor space.\u201d And so the search began for CNC machine with a small footprint and a manufacturer with a reputation for fast and accurate production results, which led Tecomet to Schw\u00e4bische Werkzeugmaschinen GmbH (SW) in Southern Germany.<\/p>\n Extensive testing delivered the proof<\/strong><\/p>\n Multi-spindle machining centers from SW had already been discussed at Tecomet back in 2013, as Senior Engineer and CNC machining enthusiast Jason Perry recalls: \u201cEven back then, we thought these machines would be perfect for the type of high-volume manufacturing we perform at Tecomet.\u201d Since the annual forecast of the major volume production cell did not justify the purchase back then, a site visit by SW remained the only result of these considerations. But the idea of multi-spindling left such a lasting impression that it was thoroughly re-evaluated in 2021.<\/p>\n Given the pandemic restrictions at the time, seeing the SW machines in action was out of the question. However, Tecomet was aware of their superior quality and reliability. \u201cThis was unknown territory for us. We were the first Tecomet site to explore the possibilities of using SW multi-spindle machining for poly products,\u201d Jason Perry says. \u201cBut working with SW to create a user requirement specification based on the existing, validated process gave us the confidence that SW fully understood our needs and expectations.\u201d Extensive development trials and very satisfactory FAT and SAT tests underlined the machines\u2019 performance and compatibility as well as SW\u2019s technical know-how. Together with a comprehensive service portfolio and an extended warranty from 1 to 2 years, it was enough to convince Tecomet to commission the first BA W02-22 machine, despite never having seen it live.<\/p>\n<\/div><\/div><\/div> Quick installation, high efficiency<\/strong><\/p>\n Going forward, everything came together quickly: it only took a few weeks between the first contact and installation. Soon, the first machine was up and running at full production capacity. \u201cThis rapid timeline was facilitated by strong and comprehensive support from SW and the high operator-friendliness of the machine,\u201d Peter Grehan emphasizes. \u201cOur employees were able to familiarize themselves with it very quickly.\u201d<\/p>\n Equipped with two spindles with 36,000 rpm and a linear drive technology, the BA W02-22 brings maximum dynamics and efficiency to the multi-step manufacturing process \u2013 from the high-quality raw polyethylene material to roughing, semi-finishing, and finishing of the tibial inserts. The plastic tibial inserts replace the cartilage in the knee implant and act as a cushion for the femoral component. \u201cWe produce multiple part sizes and thickness for either left or rights knee inserts leading to several different variations,\u201d Jason Perry explains. \u201cManufacturing these parts involves maintaining tight tolerances and managing material movement post-machining, especially for features with profile tolerances.\u201d To ensure high repeatability and robustness, each process step is fixtured on a different table, which means the fixtures do not need to be switched between operating steps. This allows the machine to run continuously, while each spindle works on a different component at the same time.<\/p>\n OEE consistently higher than average<\/strong><\/p>\n For Tecomet, manufacturing on the BA W02-22 comes with several advantages: the machine\u2019s horizontal spindle orientation supports the effective chip evacuation, maintaining the quality and consistency of the final product. Additionally, the BA W02-22’s dry machining ability \u2013 using compressed air instead of coolant for cooling \u2013 results in a cleaner process, which is essential for maintaining surface finish requirements on large articulating surfaces. The machine also requires less space to produce the same volume of parts, having roughly the same footprint as the previous single-spindle machines. And finally, the machine\u2019s easy operability has made it a favorite among the Tecomet employees: \u201cThey practically battle over who gets to work on the SW machine,\u201d Peter Grehan says.<\/p>\n Without a doubt, though, the most important benefit lies in the machine\u2019s efficiency, as Peter Grehan emphasizes: \u201cIn a nutshell, it\u2019s all about output and OEE. The main advantage of two-spindle manufacturing is having two spindles working on two parts in the same cycle.\u201d The twin rotary table and not having to change fixtures between operating steps significantly reduces operator interaction times. The machine runs nearly continuously. The only down time is for setups between product variants, which is minimum. \u201cThis is one of the main reasons for higher OEE we see on the machine from SW,\u201d Jason Perry explains. Peter Grehan adds: \u201cCompared to other machines in the cell, we produce more output per operator on it. The machine has proven to be highly reliable, precise, and efficient. It significantly enhances our production volumes and with the added advantage of 5 axis machining, helps to future proof our machining capability.\u201d<\/p>\n<\/div><\/div><\/div>![\"C\"](\"https:\/\/sw-machines.com\/wp-content\/uploads\/2024\/09\/SW_Tecomet_Maschinenbediener-Medizintechnick.jpg\")
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