Mastering Precision and Power: Barbco’s Shift to Advanced Machining with Johnford Bridge Mill
Barbco, an innovator in the trenchless boring equipment sector, embarked on a transformative journey to elevate its manufacturing process by acquiring a state-of-the-art 5-axis milling machine. Aimed at enhancing production capabilities and operational efficiency, this initiative was driven by Barbco’s commitment to delivering top-quality, durable equipment. However, the encounter with unforeseen technical challenges and operational constraints necessitated a strategic reassessment.
This case study explores Barbco’s adaptive journey in collaboration with Absolute Machine Tools, culminating in the integration of the Johnford bridge mill — a pivotal move that promised to redefine the standards of precision, rigidity, and reliability in their manufacturing operations.
The Challenges
Barbco’s ambitious endeavor to harness the advanced capabilities of a five-axis milling machine encountered significant obstacles shortly after its integration. The core issues included:
Limitations and Damage
Despite its sophistication, the 5-axis machine could not withstand the rigorous demands of heavy-duty roughing required for Barbco’s products. The aggressive machining of A36 steel, a staple in their manufacturing process known for its robustness, resulted in damage to the machine’s pivotal spindle head. This not only compromised machining precision but also led to considerable downtime due to necessary repairs, a setback that Barbco could not afford given its commitment to timely order fulfillment.
Rigidity Issues
The rigidity required for Barbco’s specific manufacturing needs surpassed the 5-axis machine’s capabilities. This shortfall directly impacted the quality and durability of the final products, raising concerns about their consistency and reliability.
Efficiency and Setup Times
The setup process for the 5-axis machine, especially for larger metal weldments used in drills and track rails, could be time-consuming, often extending to half a day. This inefficiency was exacerbated by the machine’s inability to swiftly adapt to rush orders, crucial in Barbco’s high-demand sector.
These multifaceted challenges put Barbco’s operational efficiency, product quality, and market responsiveness at risk. The need to find a solution that could reconcile the needs for robust roughing capabilities, precise fine-tolerance machining, and rapid production turnaround drove Barbco to seek an alternative that aligned with their high standards and specific industry requirements.
The Solution
In search of a resolution to their challenges, Barbco discovered an effective solution through collaboration with Absolute Machine Tools. Recognized for its extensive portfolio of cutting-edge machining solutions and exceptional customer support, Absolute Machine Tools identified the double-column Johnford DMC-4100PH 3-axis mill as the ideal match for Barbco’s specific needs.
This recommendation was the result of a thorough evaluation process that took into account Barbco’s unique requirements for precision, rigidity, and operational efficiency. The Johnford bridge mill stood out for several key reasons:
Unparalleled Rigidity and Precision
Designed with superior rigidity and stability, the Johnford bridge mill emerged as the perfect solution for Barbco’s heavy-duty roughing and fine-tolerance machining needs. Its robust construction ensures consistent performance, even when working with the challenging A36 steel, thereby meeting Barbco’s critical demand for precision down to 0.0005 inch.
Expanded Capacity
The Johnford DMC-4100PH bridge mill boasts a significantly larger table and extended work travels — 161 inches in X-axis travel and 90 inches in Y-axis travel — compared to Barbco’s previous 5-axis machine. This feature allows for the accommodation of larger parts and the setup of multiple workpieces simultaneously, drastically reducing setup times and enhancing workflow efficiency.
Heavy Part Handling
Engineered to support heavier parts, the Johnford bridge mill’s design ensures stable and precise machining of the large metal weldments used in Barbco’s drills and track rails, regardless of part size or weight.
Responsive and Proactive Service
Absolute Machine Tools’ commitment to outstanding service was a critical component of the solution. We guaranteed prompt support, responding to issues within two days or less, often exceeding expectations with same-day service. This level of customer care ensured that any potential disruptions to Barbco’s manufacturing process were quickly addressed, minimizing downtime and sustaining production momentum.
By directly addressing Barbco’s challenges with the Johnford bridge mill’s advanced capabilities and supported by Absolute Machine Tools’ industry-leading service, this strategic partnership provided a robust foundation for Barbco to not only enhance its manufacturing capabilities but also improve operational efficiency and continue to deliver high-quality, durable products.
The Implementation
The successful implementation of the Johnford DMC-4100PH bridge mill into Barbco’s operations was a carefully orchestrated process, marked by strategic planning, collaboration, and adaptation. Here are the key steps and measures taken to ensure a smooth transition and integration of the new machine into Barbco’s manufacturing workflow:
Installation and Setup
The installation of the Johnford bridge mill was meticulously planned to minimize downtime and ensure a seamless integration into Barbco’s existing production line. Absolute Machine Tools provided comprehensive support throughout the installation process, ensuring that the machine was properly set up, calibrated, and ready for operation in accordance with Barbco’s specific requirements.
Operational Optimization
With the Johnford bridge mill in place, Barbco and Absolute Machine Tools collaborated to optimize the machine’s operation for Barbco’s specific production needs. This involved fine-tuning machine settings, developing efficient machining strategies with Mastercam, and customizing workflows to maximize productivity and minimize setup times.
Training and Skill Development
The transition to G-code presented a challenge for Barbco’s team, accustomed to conversational controls and manual machines. Despite previous investments in Mastercam to aid in programming, the reliance on this software dramatically increased with the Johnford. Learning G-code proved to be a slow process, so the majority of programming responsibilities remained with Lead Programmer and Foreman Andrew Liston, who applied high-efficiency machining strategies learned on the 5-axis machine. This reliance on Mastercam for programming adjustments, accessed remotely by Liston, underscored the need for strong communication and trust between the shopfloor team and programming leads. This collaborative approach has led to operational improvements and precision in their manufacturing process.
Proactive Service and Maintenance Planning
To preempt potential issues and maintain the machine’s optimal performance, Absolute Machine Tools and Barbco worked together to establish a proactive maintenance schedule. This schedule was based on a detailed maintenance log that outlined specific service intervals for various components of the Johnford bridge mill. By staying ahead of maintenance needs, Barbco is able to ensure the machine’s reliability and longevity.
Elevate Your Manufacturing Excellence
Ready to transform your manufacturing challenges into victories? Discover the precision, efficiency, and reliability that Absolute Machine Tools can bring to your operations. Whether you’re dealing with complex machining needs, seeking to improve your production workflow, or aiming to enhance product quality, our team is dedicated to providing solutions that meet and exceed your expectations.
Join the ranks of industry leaders like Barbco and experience the difference that cutting-edge technology, backed by responsive and expert support, can make in your manufacturing processes. Don’t let operational challenges hold you back from achieving your business goals.
Contact Absolute Machine Tools today to learn more about how our tailored machining solutions can help you turn your manufacturing challenges into success stories.
