Integrated Digitization

FAMOT DIGITAL - CONTINUOUS DIGITIZATION OF THE VALUE CREATION CHAIN

DMG MORI is supporting its customers with their digitization operations by providing end-to-end solutions. DMG MORI is currently evaluating and developing how a transformation such as this can be implemented in specific terms at the plant of its subsidiary, FAMOT Pleszew Sp. z o. o. in Poland. As a model project of the future, this is where the entire value creation chain is currently being continuously digitalised with modular products and services from ISTOS, DMG MORI Software Solutions and WERKBLiQ. The end result will be unveiled before an expert audience during the grand opening on 8th October.

Founded in 1877, FAMOT Pleszew Sp. z o. o., which employs around 700 staff, is one of DMG MORI’s most traditional sites. With a total area of 50,000 m², which includes 21,000 m² of production and assembly space, FAMOT is one of the biggest production plants. And it will be the first DMG MORI production plant where everything will be continuously digital over all value creation levels. The remodelled FAMOT plant is therefore marking a milestone for the corporate group as a whole – setting an example for DMG MORI’s customers and suppliers.

By 2020, the capacity at FAMOT should be increased to more than 2,000 turning and milling machines in the CLX, CMX V and CMX U series – plus a further 2,000 machine frames.

A flexible mix of internal production and contract manufacturing

In addition to the turning and milling machines of the CLX, CMX V and CMX U series developed and produced at the site and the automation solutions the company develops itself, metal cutting is one of the fundamental pillars of its success. “Beyond meeting our own needs, our production facilities in Pleszew also act as a metal cutting service provider for the DMG MORI production network,” explains Dr Michael Budt, the Managing Director.

Doubling capacity by 2020

Around 50 networked machine tools, the majority from the group’s own “DMG MORI family”, are in operation around the clock at the moment in order to meet the enormous demand. Over 1,200 prefabricated machine frames and hundreds of sub-assemblies and components currently leave the plant on their way to the sister companies DECKEL MAHO Pfronten, DECKEL MAHO Seebach, GILDEMEISTER Drehmaschinen in Bielefeld and other group locations.

And demand is on the rise. By 2020 the capacity of the FAMOT plant will be virtually doubled to 2,000 DMG MORI machine tools and around an additional 2,000 prefabricated machine frames. To achieve this, DMG MORI will invest approx. 60 million Euros in the renovation and expansion of the site in Poland by the end of 2018. Another 20 million Euros have been budgeted for future automation projects.

The age of digitization

A considerable part of the future FAMOT project is the digitization of the entire added value chain. “What belongs together we put together digitally”, stresses the General Managing Director Zbigniew Nadstawski. He refers here in particular to the connection to the IT infrastructure of DMG MORI. All added value levels including internal workflows, systems and (automated and manual) process steps had to be seamlessly networked at the same time: From order receipt in sales through to maintenance management, and from integral production planning through to the in-house MDC / PDA software for monitoring key parameters.

“And above all we had to make our personnel digitally fit,” stresses Zbigniew Nadstawski. The management sees people as essential for concluding such a mammoth task successfully. They are convinced: “Our employees are crucial for the success of the digitization.”

Declared goals include fast, efficient and secure production processes and an overall sustainable increase in productivity, quality, transparency and response capacity. The specifications also encompassed the requirement for linking existing stand-alone solutions and new software systems into a coherent agile production network.

Digital planning solutions from ISTOS

On its way to achieving these goals, FAMOT relies on the competence of its digital sister companies within the Group. These include DMG MORI Software Solutions (in particular with its CELOS portfolio) and WERKBLiQ (with its web-based maintenance and service platform). ISTOS GmbH with its modular applications for end-to-end production planning is of special importance as well.

All parts of the system (such as order management, capture of shop floor data and overall data management) operate autonomously on the one hand, but are all linked via the so-called SERVICE BUS on the other. This takes on the role of an intermediary via which all connected applications are on a uniform data set and communicate bidirectionally.

Restructuring production at the touch of a button

The connectivity of all machines, systems and work procedures was partially already solved internally or will be ensured by the new IoTconnector.

“The resulting transparency and efficiency across the entire value creation chain is impressive,” says Mr Nadstawski, full of praise. Status messages for an order, he adds, are available at any time and at the touch of a button, right down to the machine or to the assembly station.

With regard to this specific scenario, he provides the following description: “If, for example, there is a risk of an important delivery deadline being missed, or if a time-critical component delivery is delayed, information to this effect is displayed in the PRODUCTION COCKPIT in real time. We can immediately run through various planning options, taking into account the restricted capacity and different priorities, in the PRODUCTION PLANNING module. The best alternative solution can then be triggered almost at the touch of a button across the entire process chain.”

“The connectivity of all machines, systems and processes that is necessary for this had already been established internally to some degree, or it was ensured by the new IoTconnector,” adds Dr Budt, describing a key criterion: “The existing installations are already integrated into the network over the existing MDA / PDA. The CELOS IoTconnector is used where possible and necessary.”

In addition to data exchange, the interface offers NETservice 4.0, the SERVICEcamera for visual support during a remote service call, and the CELOS MESSENGER as a fundamental introduction to monitoring and statistical evaluation of the machine condition. Manual workstations are also integrated into the data and planning cycle over what are, in some cases, mobile terminals.

CELOS - DIGITAL MONITORING

MONITORING FOR THE INTEGRAL AND SUSTAINABLE OPTIMISATION OF PROCESSES

“Digital monitoring is an ideal entry into digital transformation!” Dr. Holger Rudzio, Managing Director of DMG MORI Software Solutions, is convinced that digital transparency increases planning security as well as boosting the productivity of companies. The CELOS apps MESSENGER, CONDITION ANALYZER and PERFORMANCE MONITOR, for example, enable the integral digital analysis of the production process and in so doing pave the way towards new future-oriented fields such as predictive maintenance.

CELOS MESSENGER visualises the actual job status of the machines on the shop floor and can display machine-relevant information such as operating status, the current NC program or workpiece counter on mobile terminal devices.

This makes it possible to reduce downtimes and boost productivity as well as evaluate the profitability of jobs based on information such as machine run times, downtimes and failures. CELOS CONDITION ANALYZER simultaneously uses sensor data to visualise the component-based status of the machine. This information can be used to support preventative maintenance, for example.

CELOS PERFORMANCE MONITOR allows the capture, analysis and visualisation of the effectiveness of the entire system taking machine availability and part quality into account. All of this is good to know, says Dr. Rudzio, but the far greater value derives from having the entirety of the information at your disposal. It means you can evaluate the ramp-up curve of new machines, for example, or quantify the benefit you can expect from complementary digital products (like DMG MORI CAM system). Whatever the case, information is transformed into knowledge and knowledge in turn enables the integral and sustainable optimisation of processes.

INTEGRATED DIGITIZATION

End-to-end digitization from planning and job preparation to production and on to monitoring and service.

DMG MORI is the pioneer of digitization in machine tool building. Under the slogan Integrated Digitization, the technology leader offers a gradual entry into networked production with CELOS version 5. 27 CELOS Apps offer numerous ultra-modern and intuitive solutions for more efficiency along the entire value chain. This “digital toolbox” offers smaller companies simple and appropriate entry into digitization and larger companies modular solutions. All installed CELOS machines can be given a CELOS upgrade by a DMG MORI service technician. With this offer, DMG MORI pursues an integral digitization strategy for the entire manufacturing sector.