Multi-tasking machine tools have reduced operations to one or two, with cycle times reduced in some cases by as much as 80%, on parts previously requiring 14-15 operations.

Formed in 1995 to provide a reliable source of precision machining for its parent company, the MKW Group, Stargate Precision Engineering has now evolved into a leading practitioner of 'done-in-one' machining techniques. Now celebrating its 10th anniversary the company has a workforce of 20 and an annual turnover of GBP 750 000. During this period Stargate has relied on the best in machine tool technology, and in particular machines from Yamazaki Mazak U K, which, says Rahmon Nassor, MKW's sales and commercial director, 'Have been chosen for their accuracy, ease of set-up, longevity and user-friendly control system'.

' 'Mazak was the first company we turned to when we formed Stargate in 1995,' says Nassor'.

'I had experience of their machines and had confidence that they would achieve what we wanted in terms of accuracy and reliability.

In fact, two of the first Mazak machines we purchased are still in daily use, running 16 to 20 hours per day without any loss of accuracy.' Of similar significance to accuracy and reliability is the user friendliness of the Mazatrol control, as it allowed Stargate to diversify away from its original purpose of supporting MKW and become a fully-fledged precision engineering company in its own right'.

'Initially the bulk of production was destined for the medical industry but today Stargate tends to specialise in the manufacture of small batch quantities of highly complex components for the sub-sea, offshore and defence industries'.

'It is here that the conversational and off-line programming attributes of the Mazatrol control are proving to be highly beneficial'.

' This change in emphasis has also resulted in the development of an expertise in one-hit machining, using the multi-function capability of the Mazak Integrex 400SY and E-1060V multi-tasking machines to full effect'.

'These machines were installed recently as part of Stargate's ongoing investment programme that has already resulted in GBP 5.2 million being spent on plant and equipment'.

'The type of components now manufactured at Stargate's Gateshead, UK, facility would traditionally have been manufactured from castings or forgings''.

''However, customer demands for reduced lead times and costs are making that type of manufacturing almost obsolete and machining from solid in as few operations as possible has become the norm'.

' 'While the elimination of operations may reduce cycle times, the main driver for our business is the ability to increase throughput,' Nassor.

'Our customers are increasingly demanding reduced lead-times and costs.

Machining from solid greatly assists us in meeting these demands, as in doing so we can eliminate the lead-time and costs involved in sourcing and machining castings.

By way of example Nassor quotes numerous components where the machining process has been reduced from 14-15 operations to one or two, with cycle times reduced in some cases by as much as 80% with rework and reject parts a thing of the past''.

'''It is not uncommon,' he says, 'for us to deliver a finish machined component within 24 hours of receiving the CAD solid model from our customer.' 'What we are achieving now we could not do five years ago and this is all down to the multi-function capabilities of the Mazak machines''.