The Challenge
Automating Complex Plate Machining in a Single Operator-Run System
This customer sought to consolidate multiple machining steps into one automated system with minimal operator involvement. Key challenges included:
- Machining both sides of steel plates with high precision
- Automating loading of bar stock and slugs for part production
- Integrating gauging, washing, and rejection handling
- Maintaining single-operator simplicity across the full system
MWES was chosen for its experience in turnkey machining and robotic automation systems that handle complex material flows.
The Solution
Single-Operator Robotic Cell With Automated Machining, Inspection & Tray Packing
MWES delivered a fully integrated robotic machining system that included:
- Automated bar feed and slug loading for parts up to 4” in diameter
- Dual-headstock machining centers for face and diameter processing
- Robotic unloading, part deburring, washing, and in-process gauging
- Rejection handling and final part placement into packing trays
The cell runs independently after HMI setup and minimal operator tasks, maintaining high-speed throughput and part accuracy with automatic part handling from start to finish.
The Results
Higher ROI, Increased Throughput & Reduced Operator Burden
The MWES automation solution produced measurable benefits:
- Increased machining efficiency with continuous bar and slug processing
- Reduced need for skilled operator intervention
- Improved part consistency with integrated gauging and rejection logic
- Enabled reliable tray packing and inventory management via HMI alerts
By automating an otherwise labor-intensive process, MWES helped the customer achieve faster cycle times and consistent production with just one operator.
