MOLD SHOP OF THE FUTURE

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1 MOLD SHOP OF THE FUTURE STABLE PROCESSES

2 2 IS YOUR COMPANY READY FOR THE FUTURE? Companies and markets are increasingly exposed to the many different influential factors created by interaction in the global market place. In the medium term, increased risks as a result of price dumping and the copying craze in the low-wage countries of the Eastern hemisphere can have a detrimental effect on the actions and market access of companies that still operate profitably and destabilise them. In the longer term, this threatens the very existence of Western companies and also the local economy. Value added during the production process until products reach the end customer is decreasing steadily and profit-making opportunities are reduced to the negotiation of favourable purchasing terms. Where the production-related value creation process in a company is on the decline or ceases to operate, the company concerned can no longer survive in the market. If a company wants to continue to assert its position in the market, even in competition with cheap global suppliers, a total rethink by the management is needed regarding its manufacturing framework and response to competitors and customers. Strategies need to evolve that allow stable processes to enable the company to respond to market and customer needs in real time, quickly and flexibly, with maximum profitability, as well as to rise to the challenge of ever increasing competitive pressure.

3 3 PRODUCTION PROCESSES Deadlines are the order of the day. Internet communications enable companies to place their orders quickly, but they also mean that companies can demand changes frequently and quickly. These customer requests can play havoc with order processing. Prompt and reliable performance of an order is then often made impossible. This frequently leads to coordination problems with suppliers and logistics partners. Often, in-house processing equipment and machinery is not flexibly networked to allow compensation for these disturbances in the production process. But even faults in a company s own machinery are frequently not detected without delay making a prompt response virtually impossible. Capacity bottlenecks, lack of synchronisation of parts supply with assembly or sourcing of material and non-productive skilled personnel are then accepted as normal. Despite the Data Processing Systems that now exist everywhere and the strenuous endeavours of many employees, less than 5% of the material residence time in an industrial company is used for value added production. These materials are waiting for processing for around 95% of the possible working time, therefore tying up valuable working capital.

4 4 HARDWARE SOFTWARE Makino is an international machine tool manufacturer who is well represented in Asia, the USA and Europe. MAKINO Europe combines expertise in the field of horizontal and vertical machining centres for hard and electrodes milling with experience in Die-Sinker and Wire-Cut EDM in one company. We can therefore guarantee that our customers are always offered an optimum solution. Our aim is to contribute to the continuing success of our customers through consulting, technical evolution and support. Zwicker Systems has accumulated production automation experience since the mid eighties. Our own team of specialists is permanently engaged in further product development in Germany, Austria and the Czech Republic. Our international clients are served by distribution partners throughout Europe. Whether the customer needs a complete automation system or a detailed solution, Zwicker automation software offers increased flexibility, reduced cycle times and increased process reliability. The software enables call off of the current status of any machine from every computer station. All job and process data can be controlled in real time at the touch of a button.

5 5 WE MAKE THE DIFFERENCE We have established a strategic partnership, designed to extend the existing advantages of our products with the aim of developing a futureoriented production system featuring a complete supply chain management system for tool making and moulding. Detailed knowledge of the market manufacturing processes and many years of experience have been consolidated and are now put to use in a jointly created technology centre which serves both as a research centre and for demonstration and advisory services. MOLDSHOP

6 6 MOLDING WITH OPTIMISED EFFICIENCY Every single order creates a new challenge for production. It is usually necessary to use several different technologies to produce one end product. From the time the order is received to the delivery date, numerous components will need to be taken into consideration. From material sourcing to planning right through to production and quality control, all parts used in the manufacturing process need to be matched and must be properly synchronised, i.e. every single step must be verifiable at any time and changes must be possible at any time if needed. OPTIMUM USE OF MATERIAL OPTIMUM DEPLOYMENT OF HUMAN RESOURCES OPTIMUM USE OF TIME PERFECT QUALITY REDUCED COSTS MOLDSHOP

7 7 MOLD SHOP OF THE FUTURE The MOLDSHOP OF THE FUTURE is the new technology centre for the tool and mold making industry located in Kirchheim/Teck near Stuttgart in Germany. Come and visit us and see for yourself what we have to offer in terms of the latest manufacturing technologies. We can offer comprehensive advice. We will also take on parts of the development of future-oriented projects. PRESENTATION DEMONSTRATION ADVICE

8 8 THINK FIRST CONTROL LATER Whatever your plans, whatever investment you have in mind, the first step must always be carefully considered. Think first, control later! In order to achieve a successful solution, you need comprehensive information about the market, the latest technologies, capacities and productivity of the possible machinery options and process management systems. For this purpose, the MOLDSHOP OF THE FUTURE is the perfect forum. A team of experts will advise you on all viable technologies and facilities needed for production with optimised efficiency. In addition, we will demonstrate the use of all technologies under production conditions to you, locally! And last but not least, you will get an insight into the future of modern process management.

9 9 PRODUCTION SUPPLY CHAIN MANAGEMENT However, a manufacturing system can only function without interruption and optimally once all factors affecting production can be controlled and influenced. To achieve this, the necessary preparatory processes and supply conditions need to be determined in advance, at the supplier so that maximum transparency can be achieved. The formation of strategic alliances and the introduction of a joint production supply change management system form the basis for optimum use of capacity and maximum performance, which in turn lead the maximum added value. END- PRODUCT The production supply chain management records all required data and gives immediate access to the production status details of all parties involved. No bottlenecks No downtimes No supply problems An optimum of added value STABLE PROCESSES PRODUCTION SUPPLY CHAIN MANAGEMENT

10 10 STABLE PROCESSES To get from status A to status Z in a production unit, several technologies with carefully matched process steps need to be used. If the steps in the process lead on from one another naturally in accordance with the preset requirements and if the final result can be achieved again and again under the same conditions without any loss of time, this is known as stable technology. However, in a stable production process, it is not only the technical aspects that play an important role. There are other decisive conditions that ensure economic operation of the process. Here, it is necessary to build an inherently stable process organisation with corresponding process management. Once all the components mesh perfectly, we have a stable production process. any material any shape any speed zero tolerance highest accuracy any detail MOLD SHOP OF THE FUTURE

11 11 MODULAR STRATEGY Depending on requirements, different technologies are needed in production. This is why we pursue the strategy of modular linking, i.e. each technology viewed separately forms a stable process and can be coupled to, or extended by the other technologies. Whether individual processes or a complete production plant with all the necessary technologies are used, the modular system configuration with a hardware and software area creates a constant stable manufacturing process and ensures stable process management with real time control. Expandable future-oriented process reliability HARD MILLING GRAPHITE MILLING DIE-SINKER EDM WIRE-CUT EDM

12 12 HARD MILLING GRAPHITE MILLING Maximum precision and reproducibility with very short floor-to-floor times are your guarantee for a successful future and survival against international competition. Hard milling technology offers decisive advantages. Many component geometries can be machined without problems on suitable machinery with material hardness up to 64 HRC. The machines offered by Makino set the standards in the field of hard milling technology. A stable, low-vibration and thermally stable machine concept comparable with the best spindle technology worldwide ensures that users of our machines have a decisive advantage over their competitors. Graphite is increasingly used as electrode material in order to maximise the use of the performance potential of modern Die-Sinker machines. Graphite electrodes can be machined 8 to 10 times faster than copper electrodes. Long, ribbed and webbed sections come off the machine without delay and without the formation of flash. Used with a very precise machine and a matching extraction unit, the Makino graphite milling machine achieves a high degree of autonomy and economy.

13 13 DIE-SINKER EDM WIRE-CUT EDM Today s EDM Die-Sinker machines achieve outstanding material removal rates when used with graphite electrodes, as well as a high grade of surface finish, when used with copper electrodes. However, the most important factor for the economic use this type of installation is problem-free, accurate erosion of the Z depth. Here Makino offers a patented solution, the Z-STABILISER TECHNOLOGY, which allows to achieve stable depth accuracies of 2 µm. Modern wire erosion systems offer outstanding autonomy and reliability. The production reproducibility at the component is ±1.5 µm. This makes stringent demands both on the machine and the generator. Makino wire erosion machines meet both these requirements, and more than 1,000 users in European market will testify to this fact.

14 14 DIGITAL JOB MANAGEMENT Digital job management is a planning simulation and control instrument. On the basis of the 80:20 Pareto rule, it is used to match all resources necessary for the manufacturing process so that optimum results are achieved. A process involves the use of raw materials, machinery (technologies) and human capital and should operate under ideal conditions throughout. The raw material must be available just in time, the technologies must be stable and capable of networking, the human capital quality and quantity must meet the task in hand, and the entire process must be under continuous control and be able to respond to interfering parameters. Digital job management plans and controls a manufacturing process on an accurate and correct, now and not later basis and therefore allows planning, monitoring and, if necessary, counteractive measures in the manufacturing process in real time. Job cards and reports in hardcopy form are redundant because they could never reflect the true position. Only a manufacturing process that uses the principle of proactive feasibility assurance does not waste resources, avoids bottlenecks, ensures that deadlines are met and leads to higher process speeds, greater flexibility and increased profitability, all of which are essential for sustained competitiveness. Optimisation of the manufacturing process efficiency therefore produces perfection.

15 15 AUTOMATION OF MOLD MAKING Improved technologies and more powerful software solutions are continuing to drive mould making automation forward. Stable processes and a perfectly tuned system are essential for production. Makino and Zwicker Systems offer you the surety of a future-oriented system solution that has been tried and tested in practice and that will meet even the most stringent demands. Continuous further development and the modular system are your guarantee that your investment is fit for the future because it can be enhanced. With us, your production facilities are always state of the art, and your investment is therefore futureproof. If you would like further information and news on future developments, please ask for details of our joint MOLDSHOP OF THE FUTURE. We will be happy to help you with individual problem solutions. Stable production processes Stable processes in digital job management Effective production with optimum quality

16 MOLD SHOP OF THE FUTURE STABLE PROCESSES COME IN AND JOIN THE FUTURE! A co-operation venture between MAKINO Europe GmbH Zwicker Systems GmbH Kruichling 18 D Kirchheim unter Teck Tel.: +49 (0) 70 21/503-0 Fax: +49 (0) 70 21/