DYNA manufacturing operates using an inventory "pull" system which means, nothing is made until a customer orders product. This is the opposite of batch processing, which creates waste by running batches of parts, regardless of short-term demand. These batch processes inevitably lead to piles of work-in-process and finished-goods inventory. However rule # 1 in business and manufacturing today is to eliminate waste in all forms including inventory.

Before DYNA obtained their Mazak Multiplex 6200Y with Cut-Feeder, they machined investment castings over four operations to produce an actuator component. The lead-time to get castings resulted in having as many as 6,000 castings in the pipeline at any given point in time. In addition, the practice of batch processing increased the opportunity for scrap with each setup and handling.

DYNA’s new Multiplex turns and mills actuator components in a single set-up. Semi-machined parts don’t have to move through multiple processes. This type of machine has helped to utilize SMED (single minute exchange of die) techniques, greatly reducing setup time, scrap and labor inefficiency.  Importantly, the Multiplex can make these components out of barstock rather than investment castings, and run unattended.  Barstock is much less expensive and there’s very little lead-time to get it. In fact, DYNA’s highest volume actuators can be made out of the same diameter barstock. This has a huge impact on the time it takes to change over from one job to the next.

Rick Ruppert, Manufacturing Manager, explains that DYNA manufactures to order without finished goods inventory.

Paul Manning, Mfg. Eng., says the philosophy is to minimize labor content. "If all our machines were like the Multiplex, going from raw material to finished goods in one set-up, I would be ecstatic. I think that’s the way the machine tool industry is going. I can’t see how it can be done any other way."

Machinery Tooling & Supply provides tooling and coolant to DYNA on a consignment basis. The customer doesn’t need to worry about ordering these items because they are always there. MT&S monitors consignment levels, invoices for whatever has been used, and restocks the consignment. This helps DYNA keep their purchasing overhead low. MSI provides Barber-Colman DYNA Products with sound advice and co-develops ways of getting setup time closer to zero. MSI understands that continually improved production throughput is the best way to help our customers.