Citizen CNC technology improves manufacturing efficiency at an aerospace component manufacturer

Faced with challenges in manufacturing complex high-performance components, managing waste materials, and meeting stringent quality and precision requirements, the manufacturer Aple sought innovative solutions to streamline production. With growing market demand for precision parts, there was a need to increase output while maintaining high standards and reducing costs to stay competitive. To satisfy these needs, the company contacted Citizen Machinery UK for innovative CNC technology capable of overcoming these operational hurdles. 

About Apel: Apel Ltd, founded in 1965 near Manchester Airport, England, specialises in manufacturing aerospace components and fasteners. Their focused approach has led to consistent sales growth both in the UK and globally. The company employs technically knowledgeable sales professionals capable of addressing customer requirements and responding to RFQs.

The company offers rapid response to A.O.G (Aircraft on the ground). and other critical requirements, as well as tailored solutions for long-term agreements (LTA) and supply contracts. Apel’s comprehensive inventory control allows for more efficient batch sizes, reducing unit costs which are then passed on to customers. More about Apel 

Challenge 

As an industry leader in manufacturing aerospace-grade components, the company needed a solution to efficiently manage the challenges posed by machining complex materials like aerospace-grade stainless steel. The key issues included swarf management during production, achieving high dimensional and surface finish tolerances, and maintaining machine reliability during unattended operation. With an ever-expanding global aerospace market and increasing demand, Apel was also under pressure to meet production targets while maintaining cost efficiency. 

Despite being a seasoned player, the company faced ongoing pressure to enhance productivity while delivering precise, high-quality parts across 3,000 different part numbers. This required continuous investment in state-of-the-art machining technology to remain competitive in the global aerospace sector. Apel’s management recognised the need for cutting-edge tools that would not only meet but also exceed client requirements for tolerance, surface finish, and cost-effectiveness. 

Solution 

Apel turned to Citizen Machinery UK for solutions. Having initially invested in Citizen CNC turning centres in the 1980s, the company continues to rely exclusively on these high-precision machines to drive operational efficiency. Apel operates nine Cincom sliding-head lathes and one Miyano fixed-head lathe at its Wilmslow facility, producing around 50,000 components per month. 

The most significant technology introduced to raise efficiency was Citizen’s proprietary Low-Frequency Vibration (LFV) chip-breaking software. Integrated into three of the six 20 mm capacity Cincom L20 lathes, LFV prevents the formation of long, stringy swarf by breaking it into manageable chips during machining. This is particularly beneficial when processing aerospace-grade stainless steel bars, which constitute around 50% of the material handled by Apel. 

By using LFV, Apel significantly improved swarf management, reducing the risk of machine stoppages caused by tangled swarf. Additionally, LFV allows Apel to program the chip-breaking function selectively, activating it when required—especially for short components under 25.4 mm in length. 

The adaptive guide bush (AGB) system provided another layer of reliability. The AGB system automatically adjusts to bar diameter variations, ensuring consistency and concentricity in machining processes. This feature also reduces downtime and prevents stock seizing, allowing for uninterrupted production, particularly during unattended operations. 

Implementation 

Apel adopted LFV technology in 2018, following a visit to Citizen Machinery’s technical centre for a live demonstration. The decision to implement LFV was driven by its clear advantages, particularly in reducing the need for additional processes like centerless grinding. For components requiring high surface tolerance, LFV delivers the required finish directly, thus lowering unit manufacturing costs and improving profitability. 

The AGB system, installed across both 20 mm and 32 mm Cincom models, further streamlined operations by eliminating bar stock variations, thus maintaining the tight tolerances demanded by the aerospace industry. This system’s ability to ensure reliability during unattended operation, along with LFV’s chip-breaking capability, minimized the need for human intervention, freeing up operator time and resources. 

Results 

With the adoption of Citizen’s advanced CNC lathes and integrated technologies, Apel has dramatically increased productivity and reduced manufacturing costs. The company continues to meet the high demands of the aerospace sector while remaining profitable and competitive. LFV’s selective application has optimized machining efficiency, particularly when working with aerospace-grade materials like stainless steel, while the AGB system ensures operational consistency and quality during unattended operations.  

Paul Bowker, Quality Director at Apel, remarked on the success of the collaboration: 

“Our nine Cincoms, as well as the Miyano for turn-milling larger components, support all our production needs and will continue to do so as we expand our work in the growing global aerospace market.” 

Are you an aerospace components manufacturer struggling with machining precision parts, swarf management, and maintaining tight tolerances while boosting efficiency? 

We understand the importance of precision, reliability, and cost-effectiveness in the aerospace sector. Contact our team of CNC experts, committed to optimising your operations for maximum productivity and profitability.