Through R&D project with Buffalo Manufacturing Works, UB student helps manufacturer design automated system

BUFFALO, N.Y. – When the Curtis Screw Company of Buffalo was acquired by MacLean-Fogg last November, it was provided the means to buy equipment to support its precision-machined components operations. This enabled the company, now called MacLean Curtis, to make its own steel computer numerical control (CNC) machine blanks rather than depend on a supplier.

That got company leaders thinking: Why not apply new technology and automate the process of transporting cut blanks to the next production stage?

Thanks to assistance from Buffalo Manufacturing Works and the University at Buffalo Center for Industrial Effectiveness (TCIE), such a system is expected to debut by the end of 2015.

Instead of employees feeding 2,100 billets per day into CNC machines, a material handling system will complete the job. The blanks are used in making automotive components and sold to clients such as Ford, General Motors and Toyota.

Meanwhile, the employees responsible for manually loading the CNC machines will be trained to perform other work.

MacLean Curtis’ half-dozen manufacturing engineers are capable of designing an automated system, but don’t have the time. Plant General Manager James Frost anticipated that if the Buffalo site were to undertake the project on its own, it would be ready “about three years from now,” before adding with a laugh, “maybe.”

“Our manufacturing engineers are busy helping the operations meet growing product demand and helping implement new programs that are ensuring business into the 2020s,” Frost said.

Project gears began turning when Frost reached out to Buffalo Manufacturing Works for help.

Buffalo Manufacturing Works is a signature initiative of Gov. Andrew M. Cuomo’s Buffalo Billion Investment Development Plan. Through its operating partner, EWI, it helps innovation-driven manufacturers grow and compete by partnering with their internal engineering teams to implement technology solutions. As a Founders Council member, MacLean Curtis serves as an industry advisor to Buffalo Manufacturing Works while gaining access to its portfolio of resources and expertise.

In response to MacLean Curtis’ request, EWI tapped its partnership with UB to leverage TCIE, a university extension program that connects the business community with resources of UB’s School of Engineering and Applied Sciences. TCIE managed the project and identified Akshay Sivadas, a UB mechanical engineering undergraduate student, as the appropriate resource for the work.  

“One of our responsibilities is to provide students with experiential learning opportunities, which aligns with a priority of UB engineering dean Liesl Folks and the university as a whole,” said Timothy Leyh, TCIE executive director. “This project was an excellent way for Akshay to contribute real value to our region’s manufacturing industry.”   

Sivadas worked 12 hours per week for 13 weeks this summer under the direction of Timothy Russo, a senior manufacturing engineer at MacLean Curtis, to conceptualize the system and its robotic cell. Tasks included determining building materials, benchmarking the plant’s current systems and creating design concepts.

“It was great having an extra resource,” Frost said. “He was very enthusiastic, and excited to be here learning and contributing.”

A final design was approved for construction. Once complete, there will be eight machines supported by this blank delivery system.

The project is expected to result in approximately $105,000 in savings annually, in addition to the substantial savings afforded by in-house blank cutting.    

“Plus, we will be preventing ergonomics issues,” Frost said, explaining the repetitive moving of blanks can strain hands, elbows, backs and shoulders.