DMG MORI has revolutionized the production of its monoBLOCK five-axis machining centres with a new 4,000 square-metre (43055.64 square-foot) Excellence Factory at DECKEL MAHO Pfronten.
It’s new an automated guided vehicle (AGV) transport system resulting in a productivity increase of 30 per cent.
“Investments in innovations are the only way out of the crisis. Therefore, we are also automating and digitizing our internal value chain,” says Christian Thönes, Chairman of the Executive Board of DMG MORI Aktiengesellschaft.
The AGVs move the machines autonomously through assembly stations at a continuous speed of 45 mm/minute. Optical navigation using the latest laser scanning technology ensures a continuous process. The complete model lineup of the monoBLOCK series, including machines with palette changer (DMC) and mill-turn-table (FD), is manufactured in a flow assembly in 34 cycles – starting with basic assembly, to geometry, the machine cabinet and lastly, the final inspection.
“Today, our new monoBLOCK Excellence Factory in Pfronten already demonstrates what tomorrow’s production will look like. Using modern automation and digitization solutions, we consistently realign our locations to the production of the future,” says Michael Horn, Executive Board member of DMG MORI Aktiengesellschaft. “The driverless AGV transport system is perfectly integrated into the digital value chain of our production site. Compared to rail systems, the AGVs are a much more flexible solution, hence, optimizing the production infrastructure.”
The AGVs can also be freely navigated via remote control. The flexible timing of the machines ensures an uninterrupted and trouble-free flow during the assembly process.
With cycle times of just two and a half hours, every monoBLOCK machine can now be assembled in just seven days, which is about 30 percent faster than the previous method. This increases manufacturing capacity at the site from 600 to 1,000 monoBLOCK machines per year.
“Our goal was to increase space efficiency and to be able to produce the complete model mix of the monoBLOCK series in a highly flexible, waste-free and even more productive way,” says Reinhard Musch, Managing Director of DECKEL MAHO Pfronten.
The monoBLOCK Excellence Factory also sets new standards in terms of digitization. TULIP is an important component in the flow assembly. The US start-up’s software enables users without programming skills to create their own applications quickly and intuitively. With the help of the no-code platform, DMG MORI has developed an app solution that shows employees assembly information for each cycle with machine-specific work plans. Assembly processes of newly implemented equipment or special options is aided by detailed drawings, pictures and video instructions.
DMG has decided to pass these savings on to its customers: All prices for monoBLOCK models are reduced by about CAN$15,000
“The high demand proves that monoBLOCK machines are an important component of our portfolio,” says Horn, “With the monoBLOCK Excellence Factory, DMG MORI has created a basis for further advancing production processes and offering short delivery times with a full product mix. The new monoBLOCK Excellence Factory offers us and our customers so many advantages that we will also transfer this concept to other plants.”