The company decided to step back and re-engineer the entire machining process. This included moving up to higher performance lathes that would machine 3-foot bar sections rather than the traditional 12-foot long stock. Using the shorter lengths allowed the lathes to turn at maximum RPM, reduced waste and provided a safer work environment. However, A-Line still needed to reduce labor costs while hitting volume and delivery targets.

The solution was to equip each lathe with a Quick Load Servo S3 automatic bar feed from LNS America, Inc. (Cincinnati, OH). Says Boyce, “The automatic bar feeds are so reliable that they allow us to run completely unattended during the second and third shifts. During the first shift, we only need about 4 operator hours to set up a run and attend to all seven workstations. That’s because the operator can change over the LNS bar feeds quickly with menu-driven programming, automatic diameter adjustment and easy-to-load bar stock magazines.”

By installing the Quick Load Servo S series bar feeds, A-Line has realized a significant labor savings. Under the previous system, running the seven lathes required a full-time operator for each machine per shift. That amounts to 168 labor hours per day. Now the same production is accomplished with about 4 labor hours.

“I couldn’t be happier,” says Boyce. “We’ve had virtually no problems and minimal maintenance on these Quick Loads. The first one we installed has been running 24/7 for five years while we’ve pumped out millions of parts. It is truly the reliability of the LNS bar feeds that make it possible for us to profitably maintain and grow this part of our business.”