Process integration: the key to comprehensive performance optimization
The demands placed on today's manufacturing companies are diverse and constantly changing. In the past, workpieces that required multiple operations had to be processed by different machines in sequential steps. Now it is possible to produce these parts on a single, process-integrated machine. In an era of increasing digitalization, faster and more efficient production with a focus on sustainability is needed to meet changing requirements and applications. Against this backdrop, machine tool manufacturer DMG MORI has continuously developed its business model. Machining Transformation (MX), a holistic approach to the development of machine tools and manufacturing processes, plays a central role. This approach combines process integration, automation and Digital Transformation (DX) to create more efficient, more flexible and more sustainable manufacturing solutions and workflows, thus promoting Green Transformation (GX). The goal is to increase productivity, reduce throughput times, use resources more efficiently, and improve the quality of the parts produced. The Machining Transformation (MX) enables DMG MORI to adapt to the ever-changing demands of the manufacturing industry and to offer innovative solutions and technologies.
Process integration at DMG MORI
In the first step of Machining Transformation (MX), the intelligent mechatronic systems of DMG MORI machine tools seamlessly merge with the diverse possibilities of process integration. This synergy opens up a whole new dimension of manufacturing for customers. DMG MORI has been setting the standard for decades with its pioneering integral mill-turn combination of 5-axis milling machines and lathes. But that's not all: the company continues to drive innovation by integrating additional processes with the help of cnc grinders, cnc lasers or ULTRASONIC machining tools, as well as implementing other processes such as precision measuring or gear machining.
Maximum efficiency and accuracy through process integration
Compared to conventional step-by-step processing across multiple machines and stations, customers benefit from improved organization and a holistic increase in productivity and performance thanks to process-integrated solutions. Set-up times are drastically reduced, idle times and reclamping errors are a thing of the past, and throughput times are significantly shortened. In-process measurement ensures unsurpassed part accuracy. In addition, the integrated measurement routines combined with state-of-the-art CNC control open up new possibilities for adaptive machining processes that will revolutionize the future of manufacturing.
Process integration for enhanced efficiency: Revolutionizing manufacturing with DMG MORI
Customer benefits and value of process integration at a glance
Process integration offers customers a number of immediate benefits that make their manufacturing processes more efficient and profitable.
- Maximum efficiency and productivity: Connecting and combining multiple tasks in a single setup increases the overall efficiency and productivity of production systems. This enables integrated, faster and more cost-effective production of parts.
- Reduced setup times: Process integration significantly reduces setup times by dramatically reducing the time required to manage different platforms and switch between machining processes. This allows customers to maximize machine utilization and minimize downtime.
- Reduced idle time and errors: The integration of all the necessary machining processes into one setup eliminates the need for manual reclamping between different machines, resulting in less idle time and a significant reduction in potential errors. This ensures smooth production without unnecessary interruptions.
- Simplified process chain: Integrating multiple processes into a single fixture greatly simplifies the entire production process. This not only reduces the number of steps and machines required, but also reduces potential sources of error, further improving product quality.
- Fast job throughput: Minimizing setup and downtime reduces overall production time. As a result, you can provide customized products faster and satisfy customers.
- Improved energy balance: Combining multiple processes into one system improves the energy efficiency of the machines. This not only saves money, but also reduces the environmental footprint.
- Highest precision and quality: Process integration ensures precise and consistent machining of all components, resulting in higher quality products.
- Real-time monitoring and quality control: The machining process is continuously monitored with in-process measurements and adaptive machining processes. Any deviations can be detected and corrected immediately.
As a result, process integration leads to a significant increase in productivity compared to step-by-step machining on individual cnc machines. This has a direct impact on job planning and control, and immediately reduces the financial burden of integrated automation. Most importantly, the increased efficiency of resources used, whether energy, space, labor or internal logistics, helps to significantly reduce the environmental footprint of machining operations.
