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09/13/2016|IMTS 2016 - DMG MORI Systems

Optimum workpiece costs for every batch size

With its core competences in engineering and project management, DMG MORI Systems as a turnkey partner finds optimum automation solutions for complex manufacturing systems for its customers.

​​​​​​​In recent years DMG MORI Systems has developed to become a holistic provider of sophisticated automation solutions. Its wide range of offers include project planning of solutions, simulation and implementation of the solution on site.  In addition to the machine integrated automations of the supply plants, with their rotary or pallet storage systems, DMG MORI Systems has defined segments: the portfolio includes Standard Automation solutions for workpiece and pallet handling as well as turnkey projects with manufacturing Cells and production Systems.

The customer’s production and assembly process is critical for automated solutions. The challenge for the engineers and technicians working at DMG MORI is to understand the production system and to provide the customer with an efficient production. This is where DMG MORI Systems as a turnkey supplier comes in. The workpiece output, the technical availability of the entire system, a machining system that can be used variably, and of course quality, are the influential factors.  Thus the finished automation can ultimately be either a standard, or a customised solution. The aim is always an efficient production system that guarantees optimal workpiece costs. Quantities can vary here from one item – e.g. in moldmaking – to quantities of 2,500 items a day, as is the case in the production of cylinder heads in motor block lines.

Pooled compentencies in Wernau

In Segment 3 DMG MORI Systems develops solutions based on automation cells through to turnkey production cells.

DMG MORI Systems benefits here from DMG MORI’s many years of experience in automation solutions and its entire system competence in the achievement of these goals. As of 2016 this expertise will also be pooled (or combined) at the fully modernised plant in Wernau. With Wernau in Germany and Nara in Japan, DMG MORI Systems now has two main locations within the International Group, which focus on joint product development and project management.
The focus of modernisation in Wernau is on the competences of engineering and project management, so that DMG MORI Systems can concentrate unreservedly on Cells and Systems. In the process the former encompasses solutions based solely on automation cells through to turnkey production cells.  In other words, the combination of machining technology with the help of DMG MORI universal machines is on the one hand, and automation on the other. Systems involves holistic turnkey solutions in which DMG MORI Systems, as a general contractor, takes on the responsibility for all trades within the system. To achieve systems such as these, the automation experts utilize on the one hand, their own production modules and, on the other hand, the expertise of partners. Moreover, if desired, third-party machine tools can be integrated as part of the project, as well as the use of peripherals from our partners, such as washing machines, measuring stations and honing machines.

With core competencies in engineering and project management, DMG MORI Systems understands the production systems of the customer and wants to continue to further develop them together with the customers. “Quality, availability, innovative projects, holistic understanding, a global presence and service availability are what count in project business”, explains Jürgen Gross. DMG MORI Systems can score points with this philosophy, especially in the automotive branch.

DMG MORI Systems and Industry 4.0
Seeking transparency of production systems right through to complete production plants is given top priority in the era of Industry 4.0. Whether it is master computer solutions or an integral CAD/CAM link with CELOS– DMG MORI Systems considers the creation of systems, consisting of machine and automation that are able to optimise themselves independently when it comes to efficiency and availability, to be an important component of the future. “The use of collaborative robots will play a key role in the systems in future”, predicts Jürgen Gross. “Collaborative robots can support people wherever there are human-machine, human-assembly or human-material interfaces.” However, the necessary requirements for this will be furnished by the manufacturers of the robots themselves. “We will continue to concentrate on our core competences as a system integrator and competence partner for our customers.”Automation today plays a role in many aspects of life. In Jürgen Gross’ opinion: “We should not be afraid of this trend, but understand it rather as part of a changing world.” It entails improving all areas of everyday life, freeing ourselves of mundane tasks. “We thus gain time to concentrate on what is important and on minimizing waste.”  DMG MORI Systems expects significantly higher investments in automated production cells and production lines to be required in the future. For the CEO it is clear: “We intend to participate even more – especially with a focus on the turnkey sector.”

Robo2Go – automation can really be so simple

The aim is always an efficient production system that guarantees optimal workpiece costs. Quantities can vary here from 1 item – e.g. in moldmaking – to quantities of 2,500 items a day, as is the case in the production of cylinder heads in motor block lines.

Thanks to the use of robotic technology, investment costs in the field of automation have dropped drastically in the past few years, so that small and medium-sized enterprises are now also turning their attention more and more to the indisputable quality and cost benefits such technology has to offer. Nevertheless, a certain degree of reluctance was still noticeable in this customer segment, due to a lack of knowhow in programming in the companies on the one hand and on the other because the uncertainty of the robot not being used to full capacity remained too great a risk for those who might otherwise be interested. DMG MORI now overcomes this hurdle in one innovation leap with its newly developed Robo2Go.

The Robo2Go system excels through its flexibility. It can be used on up to four lathes if required with the aid of a lifting device, which of course maximizes investment security. In addition the system can be set up on the control panel with just a few entries, which in turn minimizes tooling times while optimizing utilization rates. All in all Robo2Go gives users a clear competitive advantage. “What makes it so special is that the robot is not programmed via the Fanuc teach pendant”, explains Jürgen Groß, Head of Sales at DMG MORI Systems. This takes place via a special Robo2Go App from the DMG MORI graphic control and operation system CELOS. So the operator needs no knowledge of robots because once configured by DMG MORI Service, the robot operates completely parameter-based via CELOS. In other words: all the operator has to do is enter the dimensions of the workpiece, the chuck and the gripper, then select one of the pre-defined arrangements of the workpiece tray and finally start the automatic process. “This innovative way of programming a robot enables especially smaller firms entry into flexible automation without the need of any expert knowledge,” Silvio Krüger, Head of Operations at DMG MORI Systems, goes on to tell us.

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