When the conversation turns to the topic of sustainability, most would assume green manufacturing and environmental protection will be the focus of the discussion. It’s part of the chat, Michael Tamasi, President and CEO of AccuRounds, argues, but to him and his company the term means much, much more. Yes, they’ve added solar panels to lower the plant’s carbon footprint; however, Michael knew building a company that will last involves attracting, developing and keeping talented staff. Retaining good employees also requires nurturing a creative and caring culture, and of course, operating a profitable business that provides long-term financial security as well as a good wage.
Investments in technology
Michael Tamasi, President and CEO
AccuRounds machines cylindrical components, often from difficult-to-machine alloys like Inconel, which has a high nickel content. They’ve developed many of their processes over the years through lots of research and development, trial and error. Each new piece of technology required a bit of a learning curve, but each addition was well worthwhile. In 1995, they began by purchasing a more CNC Swiss screw machines to replace manual machines. Since then, they’ve added 3-D printers as well as their first pieces of equipment with automation – four self-loading and unloading, vertical turning machines from EMAG (two VL 2s and a pair of VL 3 DUOs). Most recently, co-bots and robots were added to pick and supply blanks to the loading systems of machines. “The automation additions now mean that one machinist can monitor and operate three EMAG machines, and that one of the machines – a VL 3 DUO – can run for periods of time without supervision, freeing the operator for other processes,” Michael explains. AccuRounds’ relationship with EMAG began when they sought to solve a problem with chip evacuation during turning and milling processes. Increasing demand for precision components in the marketplace pushed them to purchase equipment with newer technology. They knew their aging equipment couldn’t produce parts fast enough and was too labor intensive. The old, horizontal machine designs meant metal chips backed up, expensive tooling wore out too quickly, and they couldn’t hold the polish finish requirements on critical parts.
With some research, they found EMAG and purchased their first VL 3 DUO to take advantage of the vertical design for better chip removal, which increased expensive tool life and improved component quality.
A robotic arm with drawer system added to EMAG’s VL 3 DUO means the machine can run unattended for periods of time.
Why EMAG?
AccuRounds’ EMAG machines are currently the only machines running with automation in the plant. The four do a lot of repeat work and are dedicated to producing part families for the semiconductor industry. These critical components are manufactured from Inconel, a high nickel steel alloy that is difficult to machine and very hard on tools. The job demands repeatability and precision is essential.
Automated loading and unloading features on EMAG’s VL 2 and VL 3 DUO Vertical Turning Machines mean that one of AccuRounds’ machinists can run three machines.
They chose EMAG’s vertical turning machines for the following reasons:
- EMAG’s rigid machine base increases accuracy and extends tool life, helping to control tooling costs.
- The inverted vertical axes, configuration provides ideal chip fl ow, improving cycle times thanks to fewer broken tools and the downtime necessary to change them.
- Standard self-loading and unloading automation offers the freedom and confidence to run lights out with unattended or limited supervision for 3rd shifts.
- Air sensing locators ensure components are correctly placed, ensuring high levels of repeatability.
- The small footprint of the machines means they take up less floor space, which can provide cost savings for a growing company.
- Although AccuRounds is a traditional Swiss machine house, the newly purchased EMAG machines give the company opportunities to diversify its customer base and include chucked parts in its portfolio.
- They were impressed with EMAG’s engineering team and felt confident with their purchase decision.
According to Michael, the EMAG machines have transformed AccuRounds’ productivity. “Our purchase has proven to be a very beneficial decision. It’s awesome to see the plant running today,” he says with pride. “With our EMAG VL 3DUOs, for example, we’ve been able to leverage our labor force, increase throughput and quality, and reduce scrap. All these things help us increase our capacity while consistently producing quality products.”
Attracting & retaining talent
Societal attitudes towards manufacturing work as well as an aging population make finding and keeping experienced machinists tough, Michael admits. However, to keep up with manufacturing demand, he pro-actively begins recruiting candidates when they’re as young as middle schoolers by talking to students, community leaders and school administrators about career opportunities in manufacturing, hosting plant tours, and by offering high school work/study internships. “Look,” Michael tells them, “With the desire to learn and the right attitude, it’s possible to make six figures as a machinist.” As more and more experienced machinists retire, developing new talent has become increasingly important. In addition to school-based internships, AccuRounds
nurtures in-house employees through work challenges, mentoring and tuition reimbursement for continued education. The idea is for leaders to train the next group of leaders – a concept that demands a great deal of trust in management.
“We value attitude over talent,” he explains. “We can teach them anything they need to know.”
The payback, he says, is that they can make a good wage, do interesting work and have opportunities to grow through company-sponsored higher education as well as additional vocational training.
Jenna Powers, now a third-year machinist, started working for AccuRounds in high school through a work/study program.
Path to perfection
To be part of the team, employees are encouraged to follow AccuRounds’ guiding principles for advanced manufacturing by striving for excellence in productivity and keeping manufacturing processes lean and focused.
They are asked to adopt the practices of lifelong learning and gratitude by giving back and getting involved in the community through outreach programs and manufacturing associations’ activities. Empowered and involved, each is asked to work enthusiastically as a team with trust and respect, and to lead with humility as a positive force. Leading by example, Michael received his MBA from Babson College and is very active in industry and educational organizations and has several government appointments. He currently serves as Co-Chair of the MA Advanced Manufacturing Collaborative, contributes to the SE MA STEM Network and served for eleven years as Chairman of Business Leaders United. In 2022, he became the Advisory Board Chair for Boston’s CareerSpring and helped the organization’s regional launch dedicated to helping first-generation, low-income students start meaningful careers.
AccuRounds produces highly complex, precision-critical, cylindrical components from difficult-to-machine alloys for the semiconductor, aero-space, medical instruments and oil & gas as well as robotics industries.
A little spot of Zen
Michael understands that work/life balance is more important now than ever to retain good employees. While automation and more efficient processes help AccuRounds increase productivity, precision and profitability without requiring life-zapping and costly overtime, employees are encouraged to take “mental breaks” in the company’s hydroponic, vertical garden, which is housed in a climate-controlled shipping container in the company’s back parking lot. There, they can tend to the collection of vegetables or simply take a few moments to marvel at project’s growth. Workers can pop out to the trailer and gather ingredients for a healthy lunch or take tomatoes, lettuces, carrots, Swiss chard and other greens home with them. They can also get some exercise in the onsite gym and participate with the Safety, Health & Wellness team.
AccuRounds’ “Zen Garden” – the company’s hydroponic, vertical garden, housed in a climate-controlled shipping container in the company’s back parking lot provides fresh vegetables as well as a place to quiet the mind.
What’s next?
Today, nearly 50 years from its beginnings, the company has 88 employees, 45,000 square feet of production space, and serves growing industries such as aerospace, medical instruments, semi-conductors, oil & gas as well as robotics. Although there have been challenges, Michael sees many opportunities ahead.
“There hasn’t been a more exciting time to be in advanced manufacturing,” he says.
In the past, AccuRounds expanded production capacity by increasing plant floorspace, hiring more machinists and investing in updated equipment. Each investment had its own challenges and growing pains, but each has paid off. When asked how they will continue to increase productivity and profitability within the next five years, Michael says incorporating AI for visual inspection could eliminate more errors and be much faster than current inspection procedures.
He also anticipates using new data collection technology from machinery to do things like coordinating machine production cycles and parts on order with employees’ work schedules, including lights out production whenever possible. Data collection could also help them monitor tool life, machine health and better schedule machine maintenance and tool changeovers. In addition, he believes virtual reality tools with help with employee training and machine maintenance. EMAG stands ready to assist AccuRounds with future equipment purchase plans that incorporate AI-assisted data monitoring, inspection and automation.
At first glance, the company might not seem like a typical EMAG customer; however, looking closer, one can see why this match worked out so well. Our process experts can study your unique environment –like they did with AccuRounds – and can customize equipment to meet your specific needs. Whether you produce in large volume or in a variety of smaller batches, you’ll benefit from our built-in self-loading and unloading features as well as our modular, standard platforms that can be configured to your components, other equipment and available shop space.
