emag: lights out manufacturing presentation

EMAG THAILAND • Uli Kaiser • +66 87 146 8800 • [email protected]

Lights Out Production


What is Lights Out Manufacturing?


Classic ‚Nagare‘ System Lights Out System

What is Lights Out Manufacturing?

Increasing Productivity by 20% Reducing floor space & labour cost by 50%


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



Benefit: 20% Productivity Increase



Benefit: 50% Direct Labour Cost 50% Indirect Labour Cost 50% Floor Space



Benefit: Factory Cost 120 Million Baht


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?


1. Quality: Process Capability – Good Parts •  CpK 1.67: Tolerance reduced by approx. 50% •  No need for 100% check



1. Quality: Capability vs. Good Part Integrated Gauging for critical features No manual checking after each process

Classic, ‚Nagare‘ System Integrated, automated System



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%



3. Low Cost Machine – High End Equipment Comparable Capital Investment 75% less machines Extended useful life > 10 years Reduced Life Cycle Cost



3. Low Cost Machine – High End Equipment Improved Process Capabilty – CpK 1.67 on critical features

Technical Requirements: Power and physical stability



•  Successful since 1992 •  Solid production machines for precision parts •  Vertical spindle arrangement •  Integrated automation •  Multi-tasking concept

EMAG Lights Out Manufacturing


High Rigidity – Long Tool Life

•  MINERALIT® machine bed •  Closed loop of forces •  Hydrostatic guide way •  Inherent static + dynamic stiffness



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



Physical and thermal stability reduces vibration and temperature

variations Reduced consumable cost – 30% or more



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


12 Machines for Hub Cycle Time: 60 seconds > 600,000 parts/year

Case Studies


3 Machines for Rotor Cycle Time: 45 seconds > 450,000 parts/year

Case Studies


Case Studies

2 x 2 Machines for Diff Case Cycle Time: 145 seconds > 240,000 parts/year


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


THANK YOU!

emag: lights out manufacturing presentation

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