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EMAG: Lights Out Manufacturing Presentation
- 1. EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com Lights Out Production
- 2. EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com Lights Out Production
- 3. EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com What is Lights Out Manufacturing?
- 4. 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%
- 5. 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
- 6. EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com Lights Out Manufacturing Considerations Benefit: 20% Productivity Increase
- 7. 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
- 8. EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com Lights Out Manufacturing Considerations Benefit: Factory Cost 120 Million Baht
- 9. 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?
- 10. 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?
- 11. 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?
- 12. 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?
- 13. 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?
- 14. 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?
- 15. 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
- 16. 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
- 17. 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
- 18. 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
- 19. 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
- 20. 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
- 21. 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
- 22. 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
- 23. 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
- 24. EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • ukaiser@emag.com THANK YOU!