Classic example of a digital production plant
With extensive investments and far-reaching digitalisation initiatives DMG MORI has extended and transformed the traditional Polish production plant FAMOT in Pleszew to one of the largest and most modern manufacturing facilities in the Group.
- Grand Opening in October 2018
- Investment volume totalling 60 million Euros
- Total area extended to 50,000 sqm
- First end-to-end digitisation of all added value levels
- Support from digital sister companies in the Group:
- ISTOS PLANNING SOLUTIONS
- DMG MORI Software Solutions
- CLX 450: New turning length for efficient complete machining of long workpieces
- Automation ex works from a single source
Founded in 1877, FAMOT Pleszew Sp. z o. o. with its around 700 employees is one of the most traditional of all DMG MORI plants. With investments amounting to a total of 60 million Euros, DMG MORI has extended the factory – one of the largest within the company – to a total area of 50,000 m², of which 21,000 m² are production and assembly areas, and has continuously modernised and digitised the manufacturing technologies in order to promote increased capacities and to further develop its own universal machine portfolio. The latest example is the CLX 450 with its larger turning length of 800 mm. The DMG MORI plant is the first one that operates digitally end-to-end on all added value levels. With modular products from ISTOS, DMG MORI Software Solutions and WERKBLiQ this future-oriented project serves as an example for a digital production plant. FAMOT’s extensive innovations will be presented to trade visitors at the Grand Opening on 8th October 2018.
Future production through integrated digitization
“DMG MORI supports its customers on their path to Industry 4.0 and IIoT. If we are to offer target-oriented end-to-end solutions, we also have to advance our own digitalisation, of course,” explains Dr. Michael Budt, CSO FAMOT / GRAZIANO / Ulyanovsk MT, making reference to the developments in FAMOT. “We are experiencing first-hand how digital transformation can be implemented in practice, because we are developing integral digital solutions for our production.” In this respect the regenerated FAMOT factory marks a milestone for DMG MORI as well as – with exemplary character – for customers and suppliers.
The linking of the DMG MORI IT infrastructure with regard to order management, supply chain and customer relationship was particularly decisive. All added value levels including internal workflows, systems and both controlled and manual process steps had to be seamlessly networked by FAMOT at the same time. This ranged from incoming orders in Sales to maintenance management and from integrated production planning to our own MDE/BDE software for monitoring elementary key figures for mechanical processing. Dr. Michael Budt speaks about the objectives: “This concerns efficient, fast and safe production processes as well as a sustainable increase of productivity, quality, transparency and responsiveness. The specification sheet also listed the requirement to combine existing isolated solutions and new software systems to an integrated agile production network.” Digital sister companies in the Group – in particular ISTOS with its modular applications within the PLANNING SOLUTIONS – supported FAMOT here.
A core element of the digital factory at FAMOT is the so-called “Manufacturing Service Bus”. “This open bus system enables the integration of different plant-specific applications. These include overarching applications such as ERP, HR or tool management,” summarises Dr. Michael Budt. Plus the production-oriented ISTOS application for production planning, MDE/BDE, central status visualisation among other things and for master data management and variable personnel resource planning. Other applications that communicate via the “Manufacturing Service Bus” include the web-based service platform WERKBLIQ from the DMG MORI subsidiary of the same name. Alone the over 2,000 mappings produced indicate the relevance of the “Manufacturing Service Bus”. These are (in part bi-directional) links between the fields of the different applications.
Investments in structures, technology and human resources
In view of the order and production volume that has been growing continuously for years – in the area of rump machines for the DMG MORI Group and in particular in the CLX and CMX series of our universal machine segment – modernisation of the FAMOT plant with an investment amounting to a total of 60 million Euros became a necessity, says Dr. Michael Budt and goes on: “We can now expand our capacity, ensure consistent growth in business development and continuously optimise our own range.” By 2020 the FAMOT factory is to produce more than 2,000 of its own machine tools and additionally around 2,000 rump machines plus several hundred more components and part sets for the sister companies in the Group.
The investments apply to our structures as well as our production technology. The production area today comprises a total of 21,000 m², a third of which is for assembly. There is also a large new rough casting store and a new logistics hall. 140,000 parts a day are distributed to the numerous stations in production and assembly via a KARDEX mini-load store. An inductive hardening facility – for the machining of components of the current CTX series – completes the enormous vertical integration of FAMOT. “At the heart of FAMOT is mechanical production – the largest within the group. Approximately 50 machine tools, mainly from the DMG MORI range, currently run networked around the clock to meet the huge demand.
The sustained growth also increases the need for competent employees at FAMOT – in both production and in service. As one of the largest employers in the region FAMOT cooperates with more than 15 technical schools and universities to cover this need. This development also impacts the higher-level sales and service company DMG MORI Poland. The number of engineers has doubled over the past five years and especially in service new technicians are permanently being employed and trained. Dr. Michael Budt is fully aware that: “The commitment of our employees is necessary to maintain the trust of our customers.”
CLX 450: New turning length for efficient complete machining of long workpieces
DMG MORI will be showcasing the expansion of its portfolio of universal machines at the AMB in the form of the new CLX 450 with its longer turning length. The turning centre will be presented in a version with an 800 mm turning length and counter-spindle for 6-sided machining. It has a turning diameter with Y-axis – which has a travel range of around 120 mm – of ø 315 mm. Without the Y-axis its spacious work area can accommodate components up to ø 400 mm. Bar machining up to a diameter of ø 80 mm is possible and ø 210 mm, ø 250 mm and ø 315 mm chucks are available. With its counter spindle the CLX 450 enables 6-sided complete machining of complex parts. The main spindle impresses with a high torque of up to 426 Nm. Direct travel measuring systems from MAGNESCALE in the X- and Y-axis ensure high precision, optionally also in the Z-axis. On the control-side, DMG MORI offers both SIEMENS and FANUC. This strong total package requires a mere footprint of 6.7 m², adds Dr. Michael Budt: “This means that all CLX universal turning machines from DMG MORI are available in all technological expansion options and with numerous technology cycles as well as hard and software options – and can be configured individually in accordance with the application-specific requirements of our customers.”
Automation ex works from a single source
Automation solutions are one of the most important key topics for DMG MORI, so that FAMOT has also expanded its range in this field. Customers receive a wide range of productive standard automations here ex-works from a single source. All CLX lathes can be automated by means of the new Robo2Go 2nd Generation. The robot is optionally available with 10 kg, 20 kg or 35 kg load capacity and moves workpieces up to ø 170 mm. Its dialog-guided control is easy to operate even without previous robot programming skills. A robot solution for the milling machines of the CMX V and CMX U series is the WH CELL. The modular automation system is designed for many different workpieces and is available with single or double gripper – including customised gripper jaws. The CMX V and CMX U series can also be automated by means of the PH 150 pallet handling. The load capacity is 150 kg or optionally 250 kg, while two pallet sizes are possible: ten pallets with 320 × 320 mm each or six pallets with 400 × 400 mm each.
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