Schmidt Case History - Mercury MerCruiser
Total Traceability Marking Meets Cellular Manufacturing Demands
The massive MerCruiser facility, (Stillwater, OK), which spans more than 750,000 square feet and 250 acres, serves as a worldwide manufacturing and distribution center that has produced over 2.5 million sterndrive and inboard engines for a global power boating market.
“The MerCruiser plant has evolved into a fully integrated manufacturing facility”, stated Dale Garrett, Manager of Manufacturing Engineering. “At MerCruiser we cast our major components, machine what we cast, paint what we machine, then assemble into an end product. After final testing, we package, then ship to domestic boat builder customers, as well as international distributors.”
This issue of traceability in the quality control process is critical to maintaining MerCruiser world-class product quality. “Initially we placed a serial number on the stern drives right before they were boxed", continued Garrett, “but that process did not provide us with traceability in the manufacturing process”. With the purchase of several Mazak Palletech cells a couple years ago, MerCruiser began to explore expanding their capability to ID the stern drives as part of the manufacturing process.
THE MARKING PROCESS
MerCruiser has been interested in marking for years. “There just never seemed to be a good reliable system”, stated Randy Stokes, Manufacturing Engineer. “Previously, machine operators used number stamps, but this was too operator dependant and allowed for mistakes. “It didn’t provide a reliable and accurate method to mark and track components from machining through the assembly process. ”After installation of the Mazak Palletech cells, a ballnose endmill was used to mark each part with the fixture and machine number. This used expensive machine time and decreased throughput.
The Mazak Palletech Systems enabled MerCruiser to machine parts on identical multiple fixtures in multiple machines. “With the capability to run multiple pallets of parts in several different machines, the need for a reliable marking system with minimal operator input became even more important. The machine operators needed a reliable identification method to determine which machine the parts were processed in, the specific fixture and location on the fixture. This data could then be referenced during inspections to insure quality was maintained.” continued Stokes.
The challenge then became how to integrate the marking process into the cellular system. “When we bought the Mazaks, we knew they were capable of doing certain things through the version C controller software and the Palletech system”, said Garrett. “But I think this is where Randy Stokes should be given credit for recognizing the fact that we had some opportunities for increased traceability.” It was then that MerCruiser became familiar with Schmidt Marking Systems.
DELIVERING AN AUTOMATED SOLUTION
“SCHMIDT sales engineer, John Gaast, showed us how incorporating their Styliner Stinger, a portable dot peen marking system, could deliver the identification we needed with very little operator input.” commented Randy Stokes. This would also eliminate the necessity of using machine time for identification purposes. Stokes was aware that the Mazaks incorporated a radio frequency I.D. chip on the side of each pallet and read/write heads at each load station and at each machine. 
“The information for tracking the parts was already going to the controller and actually shows up on the controller screen”, stated Stokes. “We just needed a way to send it to the Schmidt STINGER.” Stokes and the MerCruiser team engineered a “Y” data tap in between the read/write head on the load station and the controller. One signal was routed to the STINGER, which is always set to receive and the second to the Palletech controller, so both get the information they need. One of the biggest challenges was getting the data string from the Mazak controller.
Randy Stokes explained, “We had to get the serial communication ports set correctly so we could get the data. And then we had to be able to pick those numbers out of that string to actually put them into the program that the Schmidt controller uses. I worked with Schmidt for about three weeks and we finally got the process worked out.” Each system consists of one STINGER unit servicing two load stations. Operators use the hand-held STINGER units to individually code each sterndrive. Data includes the pallet number, machine number, sequential serial number, time, and date.
Stokes continued, “The STINGER was an ideal choice for this application because it’s so lightweight (only 4.5 pounds) and portable. It was easily integrated into the Palletech system.” The STINGER also features a 30’ long cable that enables MerCruiser operators to have simple access to the various sized parts and pallets as they cue up after machining.
ACHIEVING TRACEABILITY AND INCREASED QUALITY CONTROL
Because of the multiplicity of parts, pallets and cells, the new marking process enables MerCruiser not only the capability to keep an automated “running” total of production, but accurately pinpoint any machine adjustments that need to be done with regard to quality control. The system has also proved to be operator friendly. Because there can be two pallets available at one time, one on each load station, there are messages within the software that inform the operators which pallet is ready to stamp. “We were really trying to come up with a simple, low cost solution”, stated Garrett. “That was the main reason for selecting Schmidt. In addition to the hardware features, we were impressed with their ability to understand our unique needs relative to this project.” We knew Schmidt had experience with solving complicated problems similar to ours.
Both Stokes and Garrett were able to sight multiple benefits of the marking system as part of the overall palletization process. Working in three shifts, any downtime within the cell for maintenance or changeovers equates to lost productivity. We need to be able to quickly identify the root cause of the downtime. Garrett stated, “Because of the accurate time coding we can go into that system and figure out the exact time and duration of the delay.” The ability to pinpoint the delay has allowed us to improve our uptime within the cell.
“All of our personnel from machine operators to the IS department have embraced this system”, said Dale Garrett. “Going forward, our IS Department is in the process of tying the data collection into our network.” Garrett expects operator time will be reduced further because we will not need to stamp as much information on the parts. The data will instead be captured in a database on our network. “I’ll be able to view the data remotely which will streamline the entire process”, added Stokes. “Anyone within the organization with network access will be able to view the data. And with the flexibility of the Styliner Stinger portable marking system, we’ll be able to cut the 15 second per part marking time in half.” Ed Sexton, one of the group leaders for the Mazak systems, noted.
“Having the ability to quickly identify which machine a part was produced in has made making tool offsets and qualification of new parts much easier”. When asked about the overall effectiveness of the new marking system, Dale Garrett concluded, “It really wasn’t that expensive to do and it gives us a lot of information through the whole system that we didn’t have before. One thing I can say about Schmidt, the people I’ve talked to and worked with definitely know what they’re doing.”
Mercury Marine Background
Since its inception in 1939, the company that is now known as Mercury Marine has become synonymous with outboard motors. In 1961, Mercury introduced their first sterndrive engine --- the MerCruiser I --- that featured an external drive system that was attached to an inboard engine and generated over 100 horsepower. This innovation was the perfect fusion of Mercury outboard’s safety and engineering with large inboard convenience, power and fuel economy. The MerCruiser sterndrive single-handedly transformed the future of marine engine technology.
Due to the high demand of MerCruiser engines, Mercury decided to move the sterndrive production from their Fond du Lac facility to a new plant in Stillwater, OK, in 1975. Today the massive MerCruiser facility, which spans more than 750,000 square feet and 250 acres, serves as a worldwide manufacturing and distribution center that has produced over 2.5 million sterndrive and inboard engines for a global powerboating market.