This automation case study shows how Ingenious Machinery (formerly YDPM) helped a Taichung manufacturer boost capacity and quality control with round-the-clock CNC operation. By linking CNC lathes with a robot arm, the project raised daily output and stabilized quality without adding labor.
Background
A manufacturer in the Wufeng district of Taichung has produced sockets for hand tools and spare parts for motorcycles and automobiles for more than 30 years. The business started with a single CNC lathe, expanded to 12 machines and 16 employees, and passed to second-generation management.
When Mr. Hsu took over, the company ran seven CNC lathes and faced the same problems as many others: worker shortages, unstable production capacity, high quality requirements, and the need to keep up with future production trends. He decided to automate the production lines.
Production stability was the priority. Mr. Hsu initially wanted a FANUC controller with a robot arm, but because of the high initial cost, he chose an ITRI L2100 PC-based controller with a Yaskawa robot arm. The goal: no additional operators, and only one hour spent feeding raw materials.
Challenges
- Labor force shortage
- Inconsistent production capacity
- Production quality limitations
Solution
A Yaskawa GP12 robot arm linking two Ingenious Machinery ML-560S CNC lathes, each with an ITRI L2100 PC-based controller — delivering high scalability, stable quality, and maximized production capacity.
Results
In the first year of operation, the automated line handled more than ten different socket production runs with very fast changeover times. The system delivers quick turnaround, low cost, and stable quality — and the customer and Ingenious Machinery are already planning the next automation project.
Frequently Asked Questions
Q: How much can CNC automation increase production capacity?
A: In this case, daily output rose from about 2,000 to up to 2,400 pieces per day after the gripper and program were optimized, while running round-the-clock without adding operators.
Q: Which equipment was used in this automation project?
A: A Yaskawa GP12 robot arm linking two Ingenious Machinery ML-560S CNC lathes, each with an ITRI L2100 PC-based controller.
Q: Can automation handle high-mix socket production?
A: Yes. Over its first year, this line ran more than ten different socket productions with fast changeover, showing that robot-arm automation suits high-mix, frequently changing production.
Want to raise capacity and quality with round-the-clock CNC automation? Contact Ingenious Machinery (formerly YDPM) to plan a robot-arm automation solution for your factory. This robot-arm integration is part of our CNC automation & turnkey factory solutions. Learn how we tailor production line automation for each factory.
