1
Robotizing CNC machines for small
and medium series
Helmut De Roovere
CEO Aluro CNC
Reception General IT-infrastructure Finance & reporting Building infrastructure
Bending of Alu profiles www.bestbend.com
Mechanical precision parts www.aluro-cnc.com
Machines f. Insulating Alu profiles
www.aluro.com
Simply robotizing CNC www.robojob.eu
2007
Insulating Alu profiles www.isotech.be
Our organisation
Aluminium Industries OEM Manufacturing
2
2000
Market changes
1. Labor cost and gross margin
2. Bullwhip effect of the supply chain
3. Unused machining capacity
4. Decline of skilled technical staff
3
Labor cost & gross margin
2000
Market tarif CNC work 60,- €/h
Labor cost CNC operator -22,- €/h
Gross margin 21,- €/h
Machine costs -12,- €/h
Tooling costs -5,- €/h
2015
60,- €/h
-40,- €/h
3,- €/h
-12,- €/h
-5,- €/h
0 10 20 30 40
Bulgarien
Rumänien
Litauen
Lettland
Polen
Ungarn
Kroatien
Slowakei
Estland
Tschechien
Malta
Portugal
Griechenland
Slowenien
Zypern
UK
Spanien
Italien
Irland
österreich
Deutschland
Finnland
Niederlande
Luxemburg
Frankreich
Schweden
Begien
Dänemark
Labor cost EU 2014
Supply chain 2000
Part supplier OEM-Manufacture Wholesaler User
Buying Orders Assembly parts production
finished goods warehouse Parts Warehouse
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Supply chain 2014
Part supplier
OEM-Manufacture Wholesaler User
Buying Orders Assembly parts production
finished goods warehouse Parts Warehouse
Inventory = Risky
Inventory = lying money
“The bullwhip effect of the supply chain”
Reduce inventory, avoid inventory
Production capacity
Parts production
Time
Recources
24h x 365 days = 8760 h
16h x 240 days = 3840 h
machine hours
manhours
Part supplier
Parts production
• overtime
• weekend work
• night work
• Work during holidays
• Over investment
• ... .Stress
• unemployment
• insolvency
• uncertainty
• ... .STRESS
5
War for Talent
Tendency of young people,
0 to 20 years old
Tendency of older,
65 years old
Development of the labor force
20-65 years old
Shrinkage of the working
population
Summary market changes
1. Due to globalization of the market price, and the constant rise of our labor costs, our gross margin has
decreased with ± 80%
2. The way we work is no longer adapted to the flexibility demand in the supply chain
3. Our workforce is declining, it has already become very difficult to find technical people, tomorrow it will be
more difficult.
1+2+3 = Market changes are dramatic
a structural solution is necessary
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2015
Market tarif CNC work 60,- €/h
Labor cost CNC operator -40,- €/h
Machine costs -12,- €/h
Tooling costs -5,- €/h
Gross margin 3,- €/h
30% creative tasks
70% Repetitive tasks
For small & medium series
Mission
Possible results with the right automation systems, during normal working hours for the production of small and medium series
2000
Market tarif CNC work 60,- €/h
Labor cost CNC operator 22,- €/h
Machine costs 12,- €/h
Tooling costs 5,- €/h
Gross margin 21,- €/h
2015
60,- €/h
40,- €/h
12,- €/h
5,- €/h
3,- €/h
2015 + RoboJob
60,- €/h
13,- €/h Creative tasks
12+5=17,- €/h 5 € cost of Robot
5,- €/h
25,- €/h Back in business !!
In a two-shift system; 240 working days x 7.6 hours / shift = 3648 h / machine / year
30% of this time has to do with setting up = 1,094 h / year
Remaining is production time (3648-1094) = 2553 hours
While producing (2553 hours), you can make an additional gross margin of 22 € / h (= 25-3)
In one year, this is 56,166, - € per CNC machine (during normal working hours)
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Possible extra results 240 working days x 8 hours per night = 1920 hours per machine per year 44 working weeks x 2 weekend days x 24 hours = 2112 hours per machine per year Total additional capacity = 4032 hours per machine per year
0 €
20.000 €
40.000 €
60.000 €
80.000 €
100.000 €
120.000 €
140.000 €
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Possible extra results
2std/Day
4std/Day
6std/Day
8std/Day
Saterday
Parts production
Time
Resourses
24h x 365 days = 8760 h
8h x 240 Tagen = 1920 Std
Machining hours
Labor hours
Part supplier
Possible production capacity with the
right automation systems
Production capacity
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Why Robotizing CNC machines?
Realizes a separation between the creation of added-value and labor
Ensures an immediate substantial increase in gross margin
It’s the only structural solution with respect to the highly fluctuating demand as a result of the
supply chain
It makes your company structurally flexible and therefore less sensible to crises.
It is the solution to the current and growing shortage of technicians.
The role of people in production can be improved because more and more people can
concentrate on creative tasks.
This significantly increases job satisfaction.