Aerospace OEMs (original equipment manufacturers) operate in an environment that allows nothing short of total commitment to quality and performance. As a result, the industry has turned to AS9100 certification for their suppliers. The AS9100 standard contains all the requirements of ISO 9001:2000 plus nearly 100 requirements specific to the aerospace industry. In 2007, working with independent registrar SAI Global (now QMI-SAI Global), Exacta Aerospace  achieved AS9100 certification. The result is a Quality Management System (QMS) that conforms to industry standards, has a strong program for continuous improvement and is committed to customer satisfaction. Achieving AS9100 registration is a significant accomplishment that provides Exacta with a competitive advantage and recognition in the aerospace industry. But more important was the opportunity to apply the principles throughout the company and set the bar even higher in working toward their vision of becoming a leading supplier in the aerospace industry. Under the guidance of Jarrod Young, Director of Quality Assurance, annual Quality Objectives are developed and implemented to promote employee involvement. Specific goals and programs are launched addressing everything from manufacturing efficiencies and delivery time to employee training and development. The program helps everyone at Exacta understand how important their role is in meeting the company’s commitment to their customers and providing for stability and growth within the organization.
In March of 2010, Exacta would have the opportunity to test the success of this initiative through a recertification audit. The audit involves surveillance, interviews with employees and hours of document reviews by QMI-SAI Global. It also gives the employees a chance to demonstrate their understanding of processes and commitment to quality. While some companies may not be comfortable with the process, Exacta’s leadership knew their team would shine. As General Manager Ben Voegeli pointed out, “Many of the processes that are included in the QMS were developed or improved upon by the folks doing the work every day.” QMI-SAI Global Auditors Craig Stone and Sheila Miller spent several days on site at Exacta and interviewed a number of employees including CMM operator Matt Price, who really wowed them with his knowledge of the quality objectives and how they impact his job. Connie Ashcraft, Contracts Manager, not only spoke about the quality objectives but showed a clear understanding of specific processes in her area. In addition to the interviews, the auditors took time to observe the workers throughout the facility. In the Assembly Department, Rita Brooks, Assembly Mechanic performed her job following the established process perfectly as the auditor watched. The RDN database created by Database Administrator, Cheryl Zahn was cited by the auditors as a great example of multiple departments working together to identify a need for improvement and develop a tool to make that happen. In the end, the company was rewarded for their efforts by achieving recertification to AS9100 Rev. B:2004 and ISO 9001:2000 with a score of 97.2.
 

For the third year in a row, Exacta Aerospace, Inc. has signed on as a sponsor of the Wichita Bill Self Cystic Fibrosis Golf Classic, benefiting the Cystic Fibrosis Foundation. Cystic Fibrosis (CF) is a life-threatening genetic disease affecting approximately 30,000 children and adults in the United States. The CF Foundation continues to be recognized as the most effective voluntary health organization in the country by Smart Money magazine. At the national level the Foundation, in addition to fund-raising, provides valuable information about CF and support to those suffering from the illness and their families. The golf classic is a local tournament to raise money to find a cure for CF and includes a thrilling day of golf with KU men’s basketball head coach Bill Self and a VIP party for all participants. To help spread the word about the event, tournament committee members Randy Ball and Jim Eichkorn have created a Facebook page, Wichita Bill Self Cystic Fibrosis Golf Classic. To find out more about the local chapter go to www.cff.org/chapters/heartofamerica.com.

In 2005 Exacta Aerospace moved to its current facility, expanding to over 175,000 sq. ft.  In 2008, as the company celebrates 30 years in business, we are proud to announce the largest capital investment in machinery and equipment in the company's history.  The following investments represent the latest in high-speed machine tool technologies and will greatly increase Exacta's ability to provide bigger, more complex monolithic parts.

Makino D500 - The newest 5-axis vertical machining center from Makino is ideally suited for manufacturing complex parts commonly asssociated with aerospace where part quality is paramount.

• Maximum workpiece is 25.6" x 16.5".  The X-, Y-, and Z axes provide strokes up to 21.6", 39.4" and 19.7"
• Rotary table axis A and C provide rotational motion of +30 to -120 degrees on the A-axis and 360 on the C-axis
• Capable of feedrates up to 1,968"/minute, with a 14,000 rpm high power spindle
• Utilizes 3 direct drive motors for C-axis rotary able and A-axis trunnion.  One controls C-axis motion. Two control motion in the A-axis, one at each end of the trunnion.  This design provides greater torque and rigidity.  Twist and torsion in the trunnion is eliminated to achieve superior dynamic accuracy.  Ulta-high torque DD motors provide superior acceleration that can slash cycle time of complex five-axis simultaneous machining applications by up to 60%  

Exacta will utilize full-scale automation by incorporating the new machine into the existing MMC2 pallet changer alongside the 3 existing Makino A51 horizontal machining centers.

Makino MAG3 EX - The MAG series of 5-axis machining centers are the ideal product for machining medium to large aluminum airframe components.  Unparalleled metal removal rates, elimination of setup time and superior chip management have set a new standard for manufacturing efficiency.

• Travels: X-157", Y-60", Z-40"  A Axis +/-110 degrees, C Axis infinite
• 33,000 rpm, 80 hp high speed articulating spindle
• Programmable feed rates up to 1,000" /minute
• Tool storage capacity 120 with tool changing time of 10 seconds
• 140" x 60" pallet size

The MAG3 EX will be integrated into a Makino Machining Complex (MMC) Automated Pallet Handling System to provide maximum spindle utilization and permitting unattended parts production.

Mazak Quick Turning Nexus 250MY - The Mazak QTN series delivers multi-tasking capability with milling and turning in a single set up.  Quick Turn Centers have achieved productivity improvements from 40% (in steel) to 80% (in aluminum).

• Chuck Size 10", Bar Capacity 3", Maximum Swing 26.5"
• Main Spindle 4,000 rpm - 35 hp, Rotary Tool Spindle 4,500 rpm
• Tailstock

Mazak Nexus 510C/50II - The Nexus II Series combines advanced technology, productivity and value to provide top performance.  The latest generation Mazatrol Maxtrix control has been designed to be the optimum system for machining centers making this the new generation world class vertical machining center.

• Travels X-41", Y-20", Z-23"
• Horsepower - 30 hp, Maximum speed: 6,000 rpm
• Tool Storage Capacity: 24, Tool Change Time: 2.0 seconds
• Spindle Taper: #50
• Full 4th axis rotary table

Mazak Integrex 200-IV ST - Integrex is the marriage of a high-powered turning center and a full-function machining center to produce parts in a single setup.  Done-In-One machining works to eliminate multiple setups, fixtures, tools, handling and waiting time.

• Chuck Size 8", Maximum Swing 12.99"
• Maximum Length 60"
• Main Spindle 5,000 rpm - 30 hp, Rotary Tool Spindle 12,000 rpm - 25 hp
• Lower turret for simultaneous cutting

The new machinery will enhance Exacta's existing capabilities, which include:

• Complex multi-axis milling and multi-axis mill/turn
• Kitting and Assemblies
• Broaching
• Gear Shaping
• Honing
• Grinding
• CNC Waterjet
• Sheet Metal Forming
• CMM Certified Measuring
• CAD/CAM, CATIA V5
• ERP System including full MRP

Exacta Aerospace, Inc. is a leading supplier to the aerospace industry.  Founded in 1978 in Wichita, Kansas our customers include The Boeing Company, Cessna Aircraft Company, Spirit Aerosystems, Bombardier/Learjet, Hawker Beechcraft, Gulfstream and Bell Helicopter.  Exacta is AS9100 REV. B: 2004 and ISO 9001:2000 certified.

When the leadership at Exacta Aerospace, Inc. decided to take a group of production managers to the International Manufacturing Technology Show (IMTS) last week in Chicago they had a higher purpose in mind than just a road-trip. For most of them this was their first time attending the premier manufacturing technology show in North America.  They had a chance to see more than 15,000 new machine tools, controls, computers, software and processes on display including the latest innovations from well-known manufacturers such as Makino, Mazak, Mori Seiki and traditional names like Hass Automation and Bridgeport.
While the group picked up a lot of good information, clearly the highlight of the show was getting their first glimpse of the newest member of the Exacta family, the Makino D500. The newest 5-axis vertical machining center from Makino, the D500 is ideally suited for manufacturing complex parts commonly associated with aerospace. According to Makino, it provides exceptional sustained dynamic accuracy setting a new standard for 5-axis machining accuracy. The work zone for the D500 is 500 x 450 mm. The X-, Y-, and Z-axes provide strokes up to 550 mm, 1000mm and 500 mm respectively. Rotary table axis A and C provide rotational motion of +30 to -120 degrees on the A-axis and a full 360 degrees on the C-axis. The D500 is capable of rapid rates up to 50m per minute and is equipped with a 14,000 rpm high power spindle. Makino utilizes three direct drive motors for the D500’s C-axis rotary table and the A-axis trunnion. One direct drive motor controls and C-axis motion. Two direct drive motors control motion in the A-axis, one at each end of the trunnion. The dual motor design provides greater torque and rigidity. Most importantly, twist and torsion in the trunnion is eliminated to achieve superior dynamic accuracy. The ultra-high torque DD motors also provide superior acceleration characteristics that can slash cycle time of complex five-axis simultaneous machining applications by up to 60%. To gain even more efficiency from the new machine, Exacta will utilize full-scale automation by incorporating the D-500 into the existing MMC2 pallet changer alongside the 3 Makino A51 horizontal machining centers.
Exacta’s General Manager, Ben Voegeli, felt the trip was a success. “We had a great visit to the show and I think it was a positive learning experience for everyone. I will never forget the first time we attended in 2002 and the show has only gotten better. This year I came back excited that Exacta is really staying on the cutting edge of technology. The new Makino D500 we have coming our way is the first one in North America and is absolutely awesome. At times during the show the crowd around the machine was so large you could hardly get close enough to see it.”

The D500 with MMC2 pallet changer drawing courtesy of Makino