Machining Transformation (MX) by Process Integration, Automation, Digitization and Sustainability
Every 10 years, social needs change fundamentally. DMG MORI has always been evolving its business model to meet these needs with new products and services. Now, DMG MORI has matured into a provider of Machining Transformation (MX) to drive Green Transformation (GX) through process integration and automation of machine tools.
The three areas of Process Integration, Automation and Digital Transformation (DX) have an impact on Green Transformation. The social contribution consists of the resulting sustainability but also includes the solution to the shortage of skilled staff through automation as well as the development of top talent. This can be ensured through an extensive training program as part of digitalization. The goal is to focus on the qualifications of all types of employees – from engineer to machine operator.
Machining Transformation
Process Integration
5-axis opens opportunities in process integration
Workpieces that were sequentially processed by multiple machines can now be manufactured in one technology-integrated machine in a single set-up, such as a 5-axis machine or a mill-turn center to achieve higher accuracy. Following such complex technology integration, automation leads to further resource optimization, such as compensating for a lack of operators and elimination of intermediate work-in-process after each operation, which previously occupied shop floor space and costs. Digitization has helped optimize the machining process by visualizing and providing feedback from areas where operators cannot be involved due to automation.
Process Integration
High utilization of one machining center instead of partial utilization of several simple machines.
Technology Integration means that several processes such as turning, milling, grinding and measurement functions are combined in one machine tool for higher productivity. This integration reduces the number of operators needed, frees them from having to carry out multiple setups and contributes to a rewarding working environment within a company. More time can be devoted to high value-added operations, making work more rewarding for staff.
The integration of several technologies like Turn-Mill, Mill-Turn (FD), ULTRASONIC, LASERTEC and ADDITIVE MANUFACTURING (DED / DED hybrid) in a single machine tool ensures higher productivity, saves resources and reduces CO2 emissions.
42,000 rpm compactMASTER TURN & MILL Spindle for high speed and micro machining
Covering Extensive Range of Machining Across All Fields
Covering Extensive Range of Machining Across All Fields
6-sided machining with Turn & Mill Spindle compactMASTER
Overwhelming quality by perfect performance
Compact, precise, process reliable with >2 g acceleration and spindle speeds up to 60.000 1/min
Diamond tool machining with up to 3 mm / min and up to 56% lower costs per part compared to eroding
Hybrid Complete Machining: Additive Manufacturing and Milling in one Machine
Directed energy deposition combined with 5-axis milling, for building and repairing of high-value metal parts
Hybrid Machining: Additive Manufacturing and Turning / Milling in one Machine
Laser Metal Deposition & 5-axis machine
Process Integration for Enhanced Efficiency: Revolutionizing Manufacturing with DMG MORI
Automation
Automation systems for minimally attended or lights-out and / or weekend shifts
DMG MORI's range of automation systems includes workpiece handling and transport systems, pallet handling systems that transport pallets with fixtured workpieces and tool handling systems that transport cutters to the machines. The company offers a wide range, from small automation systems for single machines to automation for large production lines.
Benefits of automation
- Easier to use: Automation is not rocket science
- Proven technology: You are already using automation
- Night shifts and weekends: Let the machine work during the night
- Become more competitive: Reduce the cost per part
- Flexibility: No mass production – no problem
- Sustainability: Often 1 automated system can replace 3 stand-alone machines
Digital Transformation (DX)
From CAD-CAM solutions and post-processors to simulation
Use of digital technologies such as AI, IoT, Big Data and Digital Twin. It's about creating a competitive advantage by improving workflows and creating new business models.
The integrated Digitization approach is not only an effective method to raise productivity. The applications reduce energy consumption and therefore CO2 emissions as well, including by increasing the productive spindle hours due to faster programming at or near the machine.
Digital transformation models automatically promote green transformation: By working on Digitization, the customer can improve productivity and reduce unnecessary energy consumption. This also reduces CO2 emissions. In other words, embracing Digitization will also lead to Green Transformation.
Green Transformation (GX)
Sustainability
Technology integration saves resources and reduces CO2 emissions, automation leads to longer machine runtimes and digitization reduces power consumption for customers.
The GX approach is more than the mere reduction of CO2 emissions. It also aims to cut unnecessary work-in-progress and intermediate inventory to realize lean production anywhere in the world. GX has the potential to conserve global resources as well as transform people and the environment.
Social Contribution
The three areas of Technology Integration, Automation and Digital Transformation have an impact on Green Transformation. In addition, they thrive on the cycle of constant learning and further development. The result is a social contribution by the organization:
- Technology Integration maximizes management resources and minimizes environmental impact
- Automation helps to solve a shortage of operators
- Digital Transformation supports the development of talent through extensive training programs