AUTO-TURN MANUFACTURING

IMTS Elevates Thinking for Auto-Turn Manufacturing

Auto-Turn invested in a ROMER INFINITE 2.0 portable CMM (http://us.romer.com) whose six-axis arms offers high precision probing and optional scanning capabilities for mobile measurement, inspection and reverse engineering. This has virtually eliminated errors for Auto-Turn.

Despite the economic woes that began to plague the country shortly after IMTS 2008, Auto-Turn Manufacturing’s President Gary Shotton is sticking with his strategy to invest in making the production machine shop the model of efficiency and quality to serve a broad range of customers in the winch, drilling, oil, down-hole instrumentation and agricultural industries. 

Shotton is a relative newcomer to the machine shop world.  He purchased the company in 2006.  Auto-Turn was originally formed in 1983 with just a couple of machines and determination.  “We had a good customer base and great workers with a long history and valuable experience,” Shotton says.  He brings many years of good business sense to the table, but his single greatest skill may be his ability to listen to his seasoned managers, engineers and machinists for new ideas on achieving their overall goals. 

“We look everywhere for ideas,” Shotton is quick to point out.  “We learn from suppliers and customers.  But, IMTS is really the place that elevates our thinking.  It’s our most important resource for problem solving and production improvement.  In fact, the Ford Motor Company presentation in the Innovation Center at the show gave us many ideas on automated monitoring, reporting and ways to be more productive.”

At IMTS 2008 Shotton and his team took away two important ideas that immediately had a return on the investment.  In keeping with their march toward perfect quality, Auto-Turn invested in a ROMER INFINITE 2.0 portable CMM (http://us.romer.com) whose six-axis arms offers high precision probing and optional scanning capabilities for mobile measurement, inspection and reverse engineering.  This has virtually eliminated errors for Auto-Turn.

Automation and access to accurate data are key to Auto-Turn’s success.  Information gained at IMTS elevated the shop here too.  Auto-Turn has implemented the E2 Shop System (www.shoptech.com) shop floor software system which contains all part data including history and detail, as well as maintaining real-time control for warehouse inventory, documenting the consistent calibration of measuring instruments, payroll, machine routers, cost estimates, to name a few. 

Another idea that had sparked and then was fueled at IMTS was Auto-Turn’s quest to “get it right the first time.”  Since he purchased Auto-Turn in 2006, he and his team have devoted their energies to putting processes, equipment and machines that enable engineers and operators to embrace first article inspection and approval.  For the production shop, this practice reduces set-up time to seconds on repeat jobs.

Auto-Turn’s paperless shop floor means operator changes to an engineering file are captured electronically and the new file is saved as the master in E2 which eliminates any error on future parts.  Each machine in the shop is equipped with a webcam.  Operators use the webcam as their “note-taker” for set-ups.  The team has also embraced Skype for on-the floor questions and for communicating with customers.  “Instead of looking for someone in the building and waiting, we use voice-over-internet- protocol on our cell phones to communicate,” says Shotton.  An operator can show an image and get an answer from an engineer immediately.  It also saves travel expenses for getting answers on customer quality questions.  Auto-Turn can provide a customer with real-time images and make changes right away.

The equipment that works metal is far from overlooked.  The shop floor is a showcase for new CNC lathes, mills and complex machining centers.  The Doosan PUMA Series MX3000S turning centers (www.doosan.com) can turn and mill in a single setup.  This is an outstanding productivity booster for high volume complicated and even large parts.  Auto-Turn relies on this machine for 25 of its current jobs.  They also boast multiple Doosan Lynx 220L, HM 500 and MV3016Ls, as well as a Mori Seiki MH 500 horizontal machining center and Mazak Slant-Turn 50 horizontal lathe.  This full complement of machines keeps Auto-Turn ready for almost any job.

“Our customers see us as a partner,” explains Shotton.  “Our paperless automatic order confirmation and order shipment notification define us differently.”  He goes on to say that superior accountability sets the company apart as well.  Not only does Auto-Turn take cradle-to-grave responsibility on material and every step of machining, other support systems ensure success.  A full time inspector checks every shipment before it leaves the facility and regular in-process inspections occur with documented corrective actions

Shotton has also seen a shift in how customers think about inventory.  They want smaller orders (less inventory), but when they need parts, timing is critical.  To respond to this, the team used its creative skills to come up with a stocking strategy.  Based on projected consumption for a year, Auto-Turn will “make and hold” parts for customers, only invoicing them when the parts are shipped.  “We have to work hand-in-hand and be sensitive to how our customers are running their businesses.  This is one example of a solution we could provide.”

When asked his advice on building a thriving business in today’s manufacturing environment, Shotton answers from a positive perspective.  “It’s a cliché, but you’ve got to think outside the box,” he says.  “Listen to your suppliers, look to other industries for best practices.  Just don’t stand still.  Use your creative juices.”

As a devout Christian, Shotton brings many important perspectives to his business and management style.  “We all like systems – they make us comfortable,” he observes.  “So create good systems and don’t change them.”  He takes this lesson from the story of Creation.  Tooling might be a little less complex than Creation, but Auto-Turn’s placement and dispensing system for tooling is pure genius.  Ask Shotton about it when you see him at IMTS 2010!

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Company Information

An ISO 2000:9001 certified manufacturer, Auto-Turn Manufacturing was originally formed in 1983 with just a couple of machines and determination.  The business grew as the company made component parts for the winch, drilling, oil, down-hole instrumentation and agricultural industries.  In May of 2006, Gary Shotton purchased Auto-Turn and has nearly doubled the building size and almost 80% of the shop’s equipment are new CNC machines.  

IMTS 2010 Exhibitors Mentioned in the Story

» Romer, Inc. - Booth E-5115, Quality Assurance Pavilion, East Building
» Shoptech Software Corporation - Booth E-3952, Controls & CAD-CAM Pavilion, East Building
» Doosan Infracore America Corp & Eng Center - Booth S-8100, Metal Cutting Pavilion, South Building