Performance Partnership Enables BHI to Expand Automation and Compete Globally

BHI Corporation recently faced a decision on expansion. The obvious answer was to continue to produce, using their existing processes of multiple 4-Axis machining centers with 2-Axis turning centers (which would require the challenge of adding additional personnel); or to find a more efficient solution, they sought and found a “Performance Partnership” with Koch Machine Tool, of Houston, Texas and Methods Machine Tools, Incorporated of Sudbury, Massachusetts.

BHI, founded in 1971 in Houston, TX by Luke Brader, was approached to open facilities overseas but chose to invest in the United States. BHI had fallen into the trap so many job shops do when it comes to growth - if it works – duplicate it. The long underlying problem is when you buy new equipment to run the same old jobs; you tend to produce it as you did 30 years ago. BHI knew there had to be a better way. BHI embraced the recent advances in foreign competition and decided to excel by distinguishing themselves as a predominate player in the oilfield job shop market.

BHI Corporation, an ISO 9000 compliant company, offers engineering, turning, milling and mechanical/electrical assembly in exotic materials such as all types of inconels, stainless’, monels, ceramics, aluminums, plastics, high-strength and super alloys etc. Originally built as an oilfield job shop, they started with 2 employees, in a rented boat shed. They are now diversified into defense, aerospace, oilfield, and power generation.
BHI has 48 employees, boasts a 52,000 square foot, air conditioned facility with four overhead cranes on twenty acres in South East Houston.

Early in the thought process Brader wanted to increase BHI’s capability and efficiency with a 5-Axis machine to minimize multiple part setup. He also required a robotic pallet shuttle to keep his spindles in cut. He researched many options to best address competing globally. Tim Koch of Koch Machine Tool presented the Matsuura MAM72-63V as a solution. This machine addressed 5-Axis machining with a rugged, built-in trunion system and a robotic pallet system which allowed his traditional 4-Axis work to run.

BHI Corporation enjoys a “Performance Partnership” with Koch Machine Tool of Houston and Methods Machine Tools, Inc. of Sudbury who have made the transition into 5-Axis machining successful. According to Dave Lucius at Methods, “our goal is not to sell just another machine; we want to help companies like BHI compete globally.”

The solution grew from a 2 pallet system to a 17 pallet system that would run through the weekend. The automated tool changer ordered will accommodate up to 240 tools and will eliminate setting up tools on new jobs, as well as being able to hold “sister” tools. A laser tool setter/broken tool detector, unexpected torque detector, as well as a Renishaw In-Process measurement probe have been added to achieve the required unattended machining.

After the first machine was installed, unmanned, “lights out” machining was accomplished in a quick, efficient manner. Shortly after, BHI ordered a second machine. Mr. Brader stated, “his new goal is to have one machinist keep multiple machines running 24/7”. This “Performance Partnership” has fulfilled Mr. Brader’s goal of becoming a serious competitor in the global market while remaining in the United States and promoting American manufacturing.