Still Running Secondary Ops Like It’s 2005? Meet 10DER®

What if the biggest gain in your automated cell has nothing to do with cutting metal?

In many shops, machine tending is still treated as simple load-and-unload work. But once the cell is running smoothly, the real opportunities start to show up in everything around it that’s still done by hand.

Part marking, deburring, inspection, and small secondary ops, for example, may live outside the cycle, but with 10DER® Machine Tending Systems, they don’t have to. If the timing and layout line up, those “extra” steps can be pulled into the same automated flow, according to CNC Solutions Project Manager Kajun Roehl.

“If it’s part of the process and you can reach it, you can probably automate it,” he said. “The real gains aren’t from reinventing anything; they’re from finally tying together the steps you’ve been running separately all along.”

Deburring and Finishing Inside the Cell

Deburring is one of the most common secondary operations and the easiest to fold into automation when the process allows it. Instead of routing parts to another station, these steps can happen while the next part is already being machined.

Common finishing processes that can be integrated include:

• Countersink deburring with compliant tools

• Light sanding or buffing

• Wire brushing for edge cleanup

What changes when it’s automated:

• More consistent edge quality

• Less handling of sharp or unfinished parts

• Finishing becomes part of the flow instead of a separate step

Secondary Machining Operations

Some features just aren’t worth cluttering up your main CNC cycle, especially when they’re quick, one-and-done operations. That’s exactly where a secondary machining station inside the cell earns its keep.

Examples include:

• Automated drilling for a single feature

• Tapping operations

• Simple add-on features that don’t require a full setup

What this helps eliminate:

• Re-fixturing for one-off features

• Extra machine setups

• Additional operator handling between steps

Part Inspection in the Flow

Inspection can be handled in a few different ways depending on how tightly it needs to be integrated into production.

Common inspection approaches:

• Inspection chute: Parts are periodically diverted for manual checking

• Operator-requested inspection: A trigger drops the next part for review

• Mid-process inspection: Automated checks built into the cycle

• Mid-process inspection is especially useful when tool wear or variation is a concern. Catching issues early prevents long runs of scrap from building up unnoticed. Inspection methods can include:

• Vision systems for feature verification

• Laser systems, including through-beam checks for holes

• Automated transfer to a CMM when higher precision is required

Key outcomes:

• Stronger quality control

• Earlier detection of process drift

• Less manual inspection burden on quality teams

  
  

Part Marking Without the Extra Step

Part marking is another secondary operation that often gets handled manually simply because it is outside the CNC cycle. But it’s usually a good fit for automation.

Common options include:

• Dot peen marking stations

• Laser engraving systems

  
  

In a typical cycle, the robot can unload a finished part, load the next blank into the CNC, and then move the completed part to a marking station while machining continues.

Even though marking itself is often quick, removing it from manual work reduces interruptions and keeps production moving more consistently.

What improves:

• Consistent identification across all parts

• Less repetitive operator work

• Better use of machine runtime

  
  

Where Secondary Operations Actually Fit

Not every secondary process belongs in automation, but many do when the conditions are right. A useful way to look at it is whether the task is already part of making the finished part and whether it can be completed within the available cycle time or robot reach.

Secondary operations tend to make the most sense when:

• They don’t require a full separate machine setup

• They can happen while the CNC is running

• They reduce repeated handling of the same part

  
  

Individually, these steps may seem small. Combined, they often represent a meaningful amount of time and labor spent outside the main machining cycle.

Where the Real Gains Show Up

Once secondary operations are pulled into the same automated workflow, the impact is usually less about any single process and more about how the whole cell runs. Machines stay cutting longer, parts move less between stations, and operators spend less time on repetitive, predictable tasks.

Let’s Look at What You’re Still Doing Manually

If secondary operations are happening in your shop right now, there’s a good chance some of them can be automated without changing the core machining process.

“The key is identifying what’s being done by hand and seeing whether it fits naturally into the same cell that’s already running your CNC,” Roehl said.

If you want to explore what that could look like in your environment, that’s exactly what CNC Solutions designs 10DER systems around: finding the extra work hiding around the machine and building it into the cycle instead of leaving it on the floor.