Autonomous 5-axis precision machining around the clock

Integrated customer support from planning to series production

For optimal use of the working space, thetwo DMU 60 eVo machines have an MTSzero point clamping system embeddeddirectly in the table.

Due to the fact that it works with orders from demanding industries on a daily basis, PJK has a very customer-oriented philosophy. Peter Klein, who runs the company with his brother in the second generation, summarizes the situation as follows: “We accompany our customers from consultation to finished product, from prototype to series production.” The challenge lies in the extreme Quality requirements and the high degree of competitive pressure. Julian Klein adds: “Our components are accurate to within microns, but we also have to continuously check and optimize our processes at the same time.”One method of achieving this optimization is autonomous manufacturing. PJK has been using automation solutions to maximize the utilization of its machines since 2011. “On one hand, our employees can operate several machines during the day shift in this way, and on the other, we also use unmanned night and weekend shifts,” explains Peter Klein. This increases both the capacity and the flexibility of our production. Two of the seven DMU 60 eVo machines are connected via a pallet handling system. This has 40 pallet locations and also has room for 300 fixtures which can be swapped onto the pallets.

MTS clamping system: Space-saving andstable interface for pallet changing

For the two DMU 60 eVo machinesintegrated into the large pallet handlingsystem, DMG MORI has developed atable that has an embedded MTS zeropoint clamping system. Julian Kleinexplains the move: “The original tabletook up too much room with a fixturemounted. The new solution is flatter andhas a smaller circumference.”Thismaximizes the work area and reduces thenumber of interference contours. “Themachining also becomes more stable,which improves the precision.” PeterKlein sees a major advantage in theflexibility of the pallet handling: “Theclamping system makes it possible to useclassic pallets – also with towers forseries production – as well as equippingthem with vices on the second level.”This leads to a very wide range ofcomponents the two DMU 60 eVosystems can machine completelyautonomously.

Reliable production thanks to DMG MORI Full Service* and my DMG MORI

Being equipped with these kinds offlexible and autonomous manufacturingsolutions means that PJK needs highmachine reliability. In the case of largepallet handling, the seven DMU 60 eVomachines are in continuous use for up to22 spindle hours per day. “Longdowntimes would have a detrimentalimpact on operations,” says Peter Klein.“This is why service plays such a crucialrole in our collaboration with DMG MORI.” When it purchased the DMU eVomodels, PJK decided on DMG MORI fullservice*. The all-round, carefree packageincludes all service, travel and spare partscosts as well as annual maintenance forcustomers in Germany, Austria andSwitzerland. It includes Allianz machinebreakage insurance. “We also makeintensive use of the my DMG MORI onlineportal, because service processes arehandled transparently and quickly in thisway,” adds Julian Klein.

Digitally into the future

For optimal use of the working space, thetwo DMU 60 eVo machines have an MTSzero point clamping system embeddeddirectly in the table.

Digital solutions such as my DMG MORIare a blessing for PJK, as Peter Kleinexplains: “We utilize all of thepossibilities of digitization in both serviceand production. It starts with theCAD/CAM system and ends withcomputer-aided quality control CAQ.”The CRM also makes highly flexible orderplanning in automated productionpossible, adds Julian Klein: “For example,if a tool breaks and the machine stops,the system introduces a new tool so thatproduction doesn’t grind to a halt.” Theconsistent focus on automation anddigitization is a decisive competitivefactor. “Our further investments willtherefore also be channeled specificallyinto future-proof production.”

*DMG MORI full service is currentlyavailable in Germany, Austria,Switzerland as well as the Czech Republicand Hungary regions. For comparableoffers, please speak to your personalDMG MORI contact.