emag: lights out manufacturing presentation
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EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Lights Out Production
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Lights Out Production
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
What is Lights Out Manufacturing?
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Classic ‚Nagare‘ System Lights Out System
What is Lights Out Manufacturing?
Increasing Productivity by 20% Reducing floor space & labour cost by 50%
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Capital cost Depreciation, interest Floor space Area, consumables supply Machine availability Up time, process reliability Consumables Tools, coolant, energy Labour cost Wage rate over life cycle Labour cost Indirect cost, quality Overhead Administration, quality control Flexibility Changeover Cost Marketing Supplier to the World Total Cost per Part / Business Case Profitability
Lights Out Manufacturing Considerations
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Lights Out Manufacturing Considerations
Benefit: 20% Productivity Increase
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Lights Out Manufacturing Considerations
Benefit: 50% Direct Labour Cost 50% Indirect Labour Cost 50% Floor Space
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Lights Out Manufacturing Considerations
Benefit: Factory Cost 120 Million Baht
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
1. Quality: Capability vs.‚Good Part‘ Do Check method vs. Capability and in process gauging
2. Part Handling: Automation vs. Manual Loading Reduced Labour Cost in every aspect 320 Days / 24 hours vs. 265 Days / 20 hour Efficiency 85% vs. 60-65%
3. Low Cost Machine vs. High End Equipment Reduction of machines Improved Process Capability Reduced Consumablel Cost
Requirements for Lights Out Manufacturing?
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
1. Quality: Process Capability – Good Parts • CpK 1.67: Tolerance reduced by approx. 50% • No need for 100% check
Requirements for Lights Out Manufacturing?
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
1. Quality: Capability vs. Good Part Integrated Gauging for critical features No manual checking after each process
Classic, ‚Nagare‘ System Integrated, automated System
Requirements for Lights Out Manufacturing?
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
2. Part Handling: Automation vs. Manual Loading Reduced Labour Cost, direct, indirect and consequential Increased potential up to to 365 days/ year and 24 hours/day Efficiency 85% vs. 60-70%
Requirements for Lights Out Manufacturing?
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
3. Low Cost Machine – High End Equipment Comparable Capital Investment 75% less machines Extended useful life > 10 years Reduced Life Cycle Cost
Requirements for Lights Out Manufacturing?
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
3. Low Cost Machine – High End Equipment Improved Process Capabilty – CpK 1.67 on critical features
Technical Requirements: Power and physical stability
Requirements for Lights Out Manufacturing?
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
• Successful since 1992 • Solid production machines for precision parts • Vertical spindle arrangement • Integrated automation • Multi-tasking concept
EMAG Lights Out Manufacturing
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
High Rigidity – Long Tool Life
• MINERALIT® machine bed • Closed loop of forces • Hydrostatic guide way • Inherent static + dynamic stiffness
EMAG Lights Out Manufacturing
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
spindle motor
spindle bearing
turret
machine base electrical cabinet
Controlled Temperature for Thermal Stability
• Machine temperature follows ambient temperature • Minimum thermal variation • Capable machining process
EMAG Lights Out Manufacturing
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Physical and thermal stability reduces vibration and temperature
variations Reduced consumable cost – 30% or more
EMAG Lights Out Manufacturing
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Customers Worldwide
• DaimlerChrysler
• GM
• Ford
• GKN
• VW
• American Axle
• Getrag
• Bosch
• FAG
• Valourec
• Delphi
• INA
• Toyota
• Rexroth
• Danfoss
• KIA
• Volvo
• Caterpillar
• Hyundai
• Visteon
• BMW
• Renault
• Peugeot
• Conti Teves
• TRW
• Sachs
• Siemens
• ZF
• Borg Warner
• Honda
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
12 Machines for Hub Cycle Time: 60 seconds > 600,000 parts/year
Case Studies
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
3 Machines for Rotor Cycle Time: 45 seconds > 450,000 parts/year
Case Studies
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
Case Studies
2 x 2 Machines for Diff Case Cycle Time: 145 seconds > 240,000 parts/year
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
CASE STUDIES
8 Machines since 2000 for CV Joint Components
12 Machines since 2011 for T6 Hub Components
4 Machines since 2009 for Pump Housing
3 Machines installed Jan 2013 for Mitsubishi & Honda Brake Rotors
4 Machines in 2013 for T6 and Nissan Differential Cases
7 Machines in 2014 for MMTh, Nissan and Toyota Differential Cases
EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com
THANK YOU!
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