CNC Gantry Machine Retrofit: How We Saved Production for an Aerospace Manufacturer
In the aerospace industry, the failure of a single electronic component can jeopardize multi-million dollar contracts. This is exactly what happened to a leading structural component supplier in Illinois. Discover how IEMA US turned a potential disaster into a competitive advantage.
The Challenge
Critical Downtime and a 12-Month Lead Time for New Equipment.
A company specializing in the precision milling of aluminum fuselage components faced an emergency: their primary gantry machine experienced an unexpected total failure.
The root of the problem was an obsolete control system based on Galil controllers and Pacific Scientific (PAC-scn) drives. With these components being out of production for years, sourcing refurbished parts through unofficial channels offered no reliability.
The company was at a crossroads:
- Ordering a new machine: A cost exceeding $1.5 million and, more importantly, a 12-month lead time—far too long to meet their customers’ strict deadlines.
- A “patchwork” repair: An unacceptable risk given the precision and safety standards required by the aerospace sector.
IEMA US Intervention
Precision Engineering: Mechanical Redesign and Electronic Retrofit.
IEMA US stepped in with a comprehensive #Revamping strategy to get the asset back up and running in record time, without compromising on quality.
The project was executed in three key phases:
- Mechanical Redesign & Flanging: Since modern servomotors have different dimensions than the legacy Pacific Scientific units, our in-house engineering department designed and manufactured custom adapter flanges and couplings. This allowed for the integration of next-gen hardware onto the existing mechanical structure without altering its integrity.
- Electronics and Motion Control: We removed the obsolete Galil system, replacing it with a modern and scalable control architecture. This eliminated dependence on hard-to-find parts, ensuring the availability of standard spare parts for the next 15 years.
- Software & Data Capture: We rewrote the control logic to optimize acceleration and deceleration ramps, integrating a new touchscreen HMI. This allows operators to monitor motor loads in real-time, preventing future failures.
The Results
Production Restored in 5 Weeks with 65% Savings.
The IEMA US intervention exceeded the client’s expectations, delivering immediate and tangible results:
- Slashed Lead Times: The machine was back in operation in just 5 weeks, compared to the 12-month wait for a new system.
- Capital Expenditure (CAPEX) Savings: The total cost of the revamping was only 35% of the cost of a new machine, freeing up financial resources for other strategic investments.
- Increased Performance: Thanks to the new drives and software optimization, cycle time for each component decreased by 15%, boosting overall production capacity.
- Compliance and Safety: The system was upgraded to OSHA standards, ensuring a safer work environment and perfect data traceability for industry audits.
Want to explore the benefits of industrial revamping?
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Download our PDF brochure to discover:
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The real advantages of revamping and renewing
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Real-world case studies
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Technologies used and results achieved
Have questions? Get in touch—our team is here to help