Case Study: Lights-Out CNC Manufacturing at Precision Components Inc

Case Study: Achieving Lights-Out Manufacturing in San Diego

Precision Components Inc, a leading aerospace parts manufacturer in San Diego, partnered with Axton Robotics to implement advanced CNC machine tending automation. This case study demonstrates how lights-out manufacturing transformed their operations and competitive position.

The Challenge

Precision Components Inc faced critical operational challenges:

• Limited production capacity: Single-shift operation constrained output to 500 parts per week
• Labor shortage: Difficulty recruiting skilled CNC operators in competitive San Diego market
• High setup times: Manual part loading/unloading added 15 minutes per cycle
• Inconsistent quality: Operator fatigue led to 8% scrap rates on night shifts
• Rising labor costs: Overtime expenses exceeding $400,000 annually

The Solution: Automated CNC Machine Tending

Axton Robotics designed and implemented a comprehensive lights-out manufacturing system featuring:

Technical Specifications:

Robotic System: Collaborative 6-axis robot with 1,200mm reach and 10kg payload

Vision System: 3D part recognition and quality inspection

Part Handling: Automated raw material loading and finished part unloading

Fixtures: Quick-change gripper system for multiple part types

Integration: Direct connection to CNC control for autonomous operation

Automation Features:

• Automatic part identification and orientation
• In-process quality inspection with vision system
• Adaptive grip force for delicate aerospace components
• Predictive maintenance alerts via cloud monitoring
• Remote oversight and control capabilities

Implementation Timeline

Phase 1: Assessment and Design (3 weeks)

Comprehensive facility analysis, part flow optimization, and custom cell design tailored to existing CNC equipment and part mix.

Phase 2: Installation and Integration (5 weeks)

Robot cell installation, CNC integration, vision system calibration, and safety system implementation with minimal production disruption.

Phase 3: Training and Optimization (2 weeks)

Operator training on monitoring systems, program optimization for each part family, and fine-tuning of cycle times.

Results and ROI

Productivity Improvements:

• 200% increase in throughput: From 500 to 1,500 parts per week through 24/7 operation
• Lights-out capability: Unmanned operation for up to 16 hours overnight
• 50% reduction in cycle time: Eliminated manual load/unload delays
• 92% reduction in scrap: From 8% to 0.6% through consistent handling
• 99.7% uptime: Minimal downtime through predictive maintenance

Financial Impact:

• Annual savings: $580,000 in labor and scrap reduction
• ROI: 11-month payback period
• Revenue increase: $1.8M additional capacity annually
• Quality improvements: 100% on-time delivery for 18 consecutive months

Operational Benefits:

• Freed skilled operators for higher-value programming and quality tasks
• Eliminated repetitive strain injuries from manual part handling
• Improved employee satisfaction with more engaging roles
• Enabled acceptance of larger contracts previously impossible with capacity constraints

Lessons Learned

Critical Success Factors:

• Start with high-runner parts: Focus automation on parts with consistent demand
• Invest in vision systems: Quality inspection prevents downstream issues
• Comprehensive training: Success requires skilled oversight, not elimination of workforce
• Phased implementation: Gradual transition minimized risk and validated approach

Future Expansion Plans

Building on this success, Precision Components Inc plans to:

• Deploy automation across 5 additional CNC machines by Q2 2025
• Integrate advanced AI for predictive quality control
• Expand lights-out operation to include weekends
• Develop specialized automation for complex multi-axis machining

Industry Impact

This project has become a benchmark for CNC automation in Southern California manufacturing. The implementation demonstrates how mid-sized manufacturers can compete with larger facilities through strategic automation investments.

"The robotic machine tending system has revolutionized our business. We're now running three shifts with one shift worth of labor, producing higher quality parts, and our team is more engaged than ever. It's enabled growth we never thought possible." - Manufacturing Director, Precision Components Inc

Next Steps for Your Facility

Ready to explore how CNC machine tending automation can enable lights-out manufacturing at your facility? Contact Axton Robotics for a free assessment and ROI analysis tailored to your specific production environment.