5 DIGITAL INNOVATIONS

Mechanical engineering is currently dominated by dynamic alliances. In the interview, Christian Thönes, Chairman of the Executive Board of DMG MORI AKTIENGESELLSCHAFT, explains how the structural change is holistically reflected throughout the portfolio of DMG MORI and which future-oriented innovations customers can expect from the global market leader at EMO.

Mr. Thönes, which digital exhibits and solutions can customers expect on the DMG MORI EMO trade fair stand in Hall 2?

We are presenting more than 30 digital innovations at EMO. With DMG MORI Connectivity we are providing secure networking of not only DMG MORI machines but also selected third party machines. in addition, our CELOS customers can also carry out a PLC-independent CELOS Update to the 2019 version. This applies to every existing CELOS version from the last six years. The new DMG MORI MESSENGER for monitoring now also has an interface for third party software and can be used on all machines and devices in production that are networked with DMG MORI Connectivity. We will be demonstrating live on machines how DMG MORI NETservice as a direct remote assistant helps to reduce stoppages. We are exhibiting my DMG MORI for the first time, which is our new DMG MORI customer portal for comprehensive service optimization.

Overall we are presenting ourselves as an end-to-end partner for digitization and automation and showing how the entire manufacturing process can be consistently digitized with the modular Smart Factory products from DMG MORI, from planning and job preparation to production and on to monitoring and service.

What are the special highlights with which you provide orientation?

The focus is clearly on connectivity as far as we are concerned, as it is a basic  equirement for digitization and automation. This is why all DMG MORI machines will be equipped with connectivity free of charge in the standard version from EMO onwards. Every one of our 45 high-tech machines at EMO is also networked.

With DMG MORI Connectivity provide connectivity to DMG MORI and selected third party machines. In doing so, we are supporting all internationally established protocols such as MQTT, MTconnect and OPC-UA, plus the new “umati” language.

DMG MORI Connectivity makes it possible to connect to all significant IoT platforms such as ADAMOS, MindSphere, FANUC Field, and others are also possible. The customer chooses the direction and we set up our solutions accordingly. We will be demonstrating this openness and flexibility at EMO in monitoring applications on various platforms.

The massive opportunities that Connectivity presents also involve risks. Our customers expect appropriate security in their production networks so that they are not exposed to malicious cyber attacks on manufacturing systems. During implementation, DMG MORI Connectivity supports a multistage “Defense-in-Depth” concept. As secure operation of digital products and handling of customer information is extremely important to DMG MORI, we have integrated an “Industrial Control System”, so-called ICS Security, in our product development as core constituent of the digitization strategy.

You have just mentioned the new “umati” language. What is so special about “umati”?

The standard is “Key” and “umati” is the new standard in the machine tool industry for open and unrestricted communication within the shop floor and with higher-level IT systems.

DMG MORI has actively promoted, advanced and been instrumental in co-developing the OPC-UA based “umati” standard together with the VDW and selected partners. Now it is a case of establishing “umati” internationally and creating further standards.

How does DMG MORI support its customers with the realization of connectivity and the implementation of digital products?

We have established DMG MORI Digital GmbH together with CPRO to provide service and support for all DMG MORI Connectivity solutions. This joint venture specializes in networking machines. It supports our customers directly on site with advice and qualification and through rapid implementation of digital products from DMG MORI and partners. 

What is changing, particularly in the CELOS area?

With CELOS, DMG MORI has been the only machine tool manufacturer with an appbased control and operating system since 2013. We started with 11 apps in 2013, which were mainly for simplifying machine operation. This innovation had been future-oriented and correct. It was followed by expansion of app functionalities with approximately 50 new features per year.

Now, in 2019, we have increased the functionality significantly with a total of 25 apps and have made open integration of customized systems possible for the first time.

And we are delivering on our promise to bring all 15,000 installations on the market and all versions from the previous six years to a common level with a PLC-independent update to the new CELOS version. The data is safely migrated and all functions supported by the PLC are then fully available.

What exactly is meant by open integration?

The 2019 version of CELOS offers two major innovations. With the new APPLICATION CONNECTOR, our customers can use their own applications such as ERP and MES systems or even their own NC and production data management directly on the CELOS equipped machine. Access to information on the Internet or the Intranet can also be enabled. For example, the machine operator can immediately see shift and holiday plans or information on hazardous substances and important links via the direct connection to the Intranet. In total, up to 20 connections to CELOS can be set up as independent “apps”.

And it’s quite simple: The customer uses the SETTINGS APP to select whether they would like to access the Internet or an application in the system. After making a selection, they determine the connection destination, select a suitable name and a separate icon. At the push of a button, the new connection is then available as a separate “APP” on the user interface of CELOS.

Even deeper integration is made possible with the new job import functionality of JOB MANAGER. Orders can be directly imported into CELOS in this way. The customer no longer needs to manually transfer jobs from the MES system into CELOS, but can set up automatic transmission that makes data exchange with CELOS possible. A prerequisite for direct import is that the customer MES system makes the orders available in the job-specific .cba format and stores it in the specified directory within CELOS.

Openness is also provided with DMG MORI MESSENGER at EMO with the CELOS update. For the first time, we are not only offering CELOS functionality for DMG MORI machines but for all devices on the shop floor networked using DMG MORI connectivity, i.e. also for third party machines.

A great deal of customer feedback has augmented the redevelopment of DMG MORI MESSENGER. In this way, the MESSENGER now enables simple machine data acquisition and provides an open database for third party software. Reports can be generated automatically and clearly displayed on a page. The dashboard of the MESSENGER can be configured individually. Customers can see all relevant information about the status of the machines at a glance.

We are convinced that the new DMG MORI MESSENGER is the best monitoring product in our industry.

Monitoring is an important factor for increasing productivity in manufacturing. For this reason, as a special EMO offer, users of machines with CELOS will receive the latest CELOS version including the new MESSENGER and DMG MORI Connectivity for their machines as a package. Also included is access to the DMG MORI NETservice limited to 2 years and unlimited access to our new customer portal my DMG MORI.

my DMG MORI?

my DMG MORI is our new customer portal with which users can organize and optimize all service processes regarding their DMG MORI machines.

Our customers previously had to contact the DMG MORI service hotline by telephone for any request, regardless of whether they merely needed one manual or required a service call. With my DMG MORI, every customer can now send service requests directly online, track the status of the request in real time and access all documents in a comprehensive library, around the clock. Our customers can even view requests that have been dealt with via the NETservice.

In combination with NETservice, my DMG MORI provides comprehensive transparency across all service processes and procedures.

… my DMG MORI can only be used for DMG MORI machines, right?

Of course, the advantages of my DMG MORI relate to DMG MORI machines. However, we also have WERKBLiQ, which is a platform that can also be used for third party products. All information from my DMG MORI is imported and displayed, of course.

WERKBLiQ therefore provides an integrated solution for the digital shop floor for managing documentation in a central location, controlling service operations with precision, implementing maintenance in an effective way and learning continuously through evaluation.

When you talk about the openness of DMG MORI with regards to connectivity with IoT platforms, what role does ADAMOS play in the digital strategy of DMG MORI?

The basic idea of ADAMOS is without alternative, mechanical engineering designs solutions for mechanical engineering, its suppliers and its customers. The partner network is expanding continuously, meaning that 16 well-known companies are now actively working together. The implementation of digital applications is supported by the strong network of certified enabling partners.

The exchange of information in the partner network is very positive, as we are united by the firm conviction that we can only deal with the challenges of digitization together. This is how we benefit from Hackathons and co-innovation projects. Successfully dealing with the digital future together is the main focus of our activities. All partners bundle their know-how in order to understand better and faster the needs of the market. It is important to develop integrated solutions for the digital factory to drive new business models and set standards for the industry. More than 40 product ideas have emerged to date, which have flowed into new services and applications, among other things. 

At EMO, ADAMOS is presenting its range of applications for the digital customer experience for the first time via the ADAMOS APP Store. Ease of use represents the core of every offer for end users on the shop floor. Machine operators are looking for universal, simple, manufacturer-independent solutions. ADAMOS provides the required tools, technologies and services for a broad and relevant range of digital solutions. The offer includes the first horizontal applications such as the ADAMOS-OEE app, integration with WERKBLiQ from DMG MORI and 10 other solutions.

ADAMOS provides the relevant technology for rapid development of applications with its IoT platform. To ensure that the devices of the DMG MORI Connectivity solution can be managed, DMG MORI uses “Device Management” from ADAMOS. Best-in-class products from ADAMOS are used. With “Device Management”, DMG MORI connects all machines, systems and devices with the IoT platform.

Which strategy are you following during the development of digital products to market readiness?

Initially we use our digital products internally, learn from users, implement the feedback and then release the result onto the market as a tried and tested solution. For example, customers can convince themselves of the digital maturity of our products by visiting our digital factory in FAMOT. 700 employees work simultaneously at 180 work stations with more than 50 machines on up to 11,000 orders in FAMOT. A total of 10 applications are synchronized.

To make this highly efficient manufacturing procedure possible, all processes have been digitized, starting with planning. Whereas we previously needed six employees for manual planning, now two are sufficient. The fully integrated control system makes flexible, detailed planning possible to suit the available capacity. Error-prone planning using Excel can be completely replaced with an automated and integrated system. The basis is an integrated layer that centrally manages all systems.

We also use the WERKBLiQ maintenance platform to control the entire maintenance process of all production machines from a centralized application in FAMOT. We manage more then 60 scheduled maintenance orders per day. The basis for machining on more than 50 installed DMG MORI machines at FAMOT is connectivity.

DMG MORI stands for high-precision machine tools and provides solutions for fully digitized shop floor processes. In this way, we provide a unique basis for actively shaping the future of all facets of manufacturing technology, together with our customers.

It is therefore perfectly clear that we will continue to invest in digitization, develop products with a focus on customer benefits and participate in new start-ups if appropriate.