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Parent CompanySystem 3R International AB Sorterargatan 1S-162 50 VällingbyTel: +46 (8) 620 20 00Fax: +46 (8) 759 52 34 E-Mail: [email protected]
Czech Republic
System 3R Czech s.r.o.Tiskarska 10/257CZ-108 28 Praha 10MalesiceTel: +420 (2) 34054 224Fax: +420 (2) 34054 225Mobile: +420 (6) 02378 495e-mail: [email protected]
Far East & ChinaSystem 3R Far East Pte, Ltd.6 Harper RoadLeong Huat Building, # 01-01Singapore SG-369 674Tel: +65 6289-4811Fax: +65 6289-3011e-mail: [email protected]
France, Spain & PortugalSystem 3R France S.A.S.Z.I des Richardets14-16 Rue du BallonFR-93160 Noisy le GrandTel: +33 (1) 43 05 47 11Fax: +33 (1) 43 05 81 63e-mail: [email protected]
Germany, BeNeLux & AustriaSystem 3R Vertriebs GmbHWasserweg 19DE-64521 Groß-GerauTel: +49 (6152) 80 02-0Fax: +49 (6152) 80 02 35e-mail: [email protected]
ItalySystem 3R Italia SRLVia Giotto 2/4IT-20040 Cambiago (MI)Tel: +39 (2) 95 34 50 95Fax: +39 (2) 95 34 50 96e-mail: [email protected]
Japan & KoreaSystem 3R Japan CO., Ltd.5-18-5, KoishikawaBunkyo-Ku, Tokyo JP-112
Tel: +81 (3) 3944 5411Fax: +81 (3) 3944 5911e-mail: [email protected]
ScandinaviaSystem 3R NordicSorterargatan 1SE-162 50 VällingbyTel: +46 (0)8-620 20 00Fax: +46 (0)8-38 81 84e-mail: [email protected]
Järfälla HärdverkstadElektronikhöjden 8SE-175 26 JärfällaTel: +46 (0)8-580 144 70Fax: +46 (0)8-580 126 55e-mail: [email protected]
SwitzerlandSystem 3R AGWilerstrasse 98, CH-9230 FlawilTel: +41 071 394 13 63Fax: +41 071 394 13 60e-mail:[email protected]
Mecatool AGWilerstrasse 98, CH-9230 FlawilTel: +41 071 394 13 50Fax: +41 071 394 13 60e-mail: [email protected]
TurkeySystem 3R Hassas BaglamaEkipmanlari Tic. Ltd. Sti.Rami Kisla Cad. APEK Üretmen ls Merkezi A Blok No: 89 / 146Topçular 34140 Eyüp IstanbulTel: +90 (212) 613 8062 – 8063Fax: +90 (212) 613 8069e-mail: [email protected]
United KingdomSystem 3R (UK) Ltd.2 Duke Street, Princes RisboroughBuckinghamshireHP27 OAT EnglandTel: +44 (1844) 27 44 55Fax: +44 (1844) 34 88 00e-mail: [email protected]
USA & CanadaSystem 3R USA Inc.40-D Commerce WayTotowaUS-NJ 07512Tel: +1 (973) 785-8200Fax: +1 (973) 785-9612e-mail: [email protected]
3HP, 3R, 3Ready-to-Run, 3Refix,3Robomatic, Combi, Delphin, Dynafix, One Minute Set-up, One System Partner,Macro, R2R, System 3R, VDP, WorkMan,WorkMaster, WorkPal, WorkShopManagerand Zerofix are registered trademarks ofSystem 3R.
Issue 6
The Newsletter of System 3R Group
Designed and produced by Javelin Communications · Tel: +44 (0)1494 601010 · E-mail: [email protected]
www.system3r.comwww.system3r.com
There’s no getting away from it – China isbig! A population of 1.3 billion people in acountry of 9.6 million square kilometreswith a speed of economicgrowth that is breathtaking.
In China you will find theentire spectrum ofproduction – from thelowest quality to the highest– all driven by a‘frightening’ energy you canalmost feel. From theindustrialised regions on theeast coast the pace ofprogress is movinginexorably westwards,where there is huge potential. The effect ofthis heated Chinese market on the pricesof steel and other raw materials is plain tosee.
Today, China is beyond doubt “the factoryof the world” in electronics and whitegoods , with the next wave of newcompanies predicted to be in theautomotive industry. Several major playersare already in place, but many more arequeuing up to join them. The main reasonis the cost level, which is generally verylow, but accessibility to the largest potentialmarket in the world is what makes it soattractive.
It is in this hectic environment that System3R Far East operates.
System 3R China – a rising starShanghai and BeijingThe company started in 1996 in Shanghai,where Jonathan Zhang moved to from
Singapore to set up ourfirst local office in Chinawith Kitty Tang as adminsupport. The year after, asales office was opened inBeijing.
Today, System 3R FarEast’s operation inmainland China involves asales team of six, backed upby an administrator – allsupporting some 30
distributors throughout this vast country.And they do it effectively – with System3R Far East’s operation on the Chinesemainland accounting for about 60% of itstotal sales, even after such a short time.
Although the average age of our team isbelow 30, all of them are well-trainedsystem engineers with sound experience ofthe machine sector or of tool production.And they don’t just sit at their desks. Ittakes each of them 200 days’ travelling toback up the distributors in the field. DavidZhang is well aware that, whilst one deal infive is made with a direct customer, theother four are made through theirdistributor network.
In 2001, the Shanghai operation moved to
IN THIS ISSUEJIMTOF 2004
EXHIBITION REPORT
THE FUTURE OFMOULDMAKING
ITALY’S DYNAMIC DUO
PRODUCTIVITY GAINSOUTPACE PEDAL
POWER
EQUIPPING THEWORLD’S LARGEST
TOOLROOM?
AUTOMATION BRINGS ITS OWN REWARDS
WORLD ROUND-UP
new premises, strategicallysited in Xinzhuang –Shanghai’s geographical centreand near Asia’s largest trafficintersection of 11 roads! Thismakes it easy for fast access tothe nearby provinces ofZhejiang and Jingsu, both ofwhich are undergoing rapid industrialdevelopment.
Phenomenal growth & developmentJonathan Zhang talks about the rapid paceof development: “A lot has happened sincewe started here in Shanghai nearly tenyears ago. Those days were dominated bylabour-intensive manufacturing withrelatively low quality output, alongside acertain amount of medium qualityproduction. Today we find the entirequality spectrum, with high qualityproducts accounting for an ever greatershare. And the export share is increasing allthe time.”
Jonathan continue, “The figures speak forthemselves. In 1995, 250 imported EDMmachines were sold. In 2004, expectedsales are 5,000 EDM machines and10,000 CNC milling machines! The five
major EDM machine manufacturers alone- Agie, Charmilles, Makino, Mitsubishiand Sodick - sold 250 machines in 1995,1, 600 machines in 2003 and 2, 400machines expected sales in 2004. Verysubstantial growth, but with one majorreservation. Today, machine manufacturerscan only charge half what they couldcharge ten years ago – with margins verydifferent from what they once were.”
A defined strategy pays dividends“This means that, over time,manufacturers will be delivering theirmachines ‘bare’,” Jonathan continues.“There’s simply no room for accessories
when price pressure is sosevere. As a consequence,System 3R don’t get any “freeorders” when machines aresold. Instead we have to huntdown every order ourselves!
“If you then consider that theprice of tools is still on the same level asten years ago, meaning that it’s becomesignificantly more expensive to invest intools than in machines, you realise that it’sby no means easy to conclude deals. Onthe other hand, 90% of all EDMmachines are still being operated without areference system. So there are still plenty ofopportunities for us.
“The size of the country dictates that wefollow a defined strategy which focusesprimarily on “system customers” -medium-sized and large mould toolmakers producing at least 30 mould toolsa month. Generally, the management ofthese companies are open to the positiveeffects of a reference system – increasedaccuracy, shorter lead times and fewerrejects, all of which ultimately lead togreater productivity.”
Victor Yang of the Beijing office takes upthe story: “This is, however, along process, since our workisn’t finished when theproducts have been deliveredto the customer. Delivery isfollowed by the installation ofspindle and table chucks, andthen by the training of themachine operators. After all,there’s no point investing inequipment to boostproductivity without learningto take advantage of theopportunities available.During this period we spend alot of time with the operators
and what matters here is wu-wei – actionwithout action – in other words, gettingsomething done by intervening as little aspossible!”
The fact that this strategy has proved to beso effective can be seen not least at System3R’s main factory at Vällingby, Sweden,where they have now invested in newmachines to meet an ever-growingdemand, not least from the burgeoningChinese market.
Jonathan Zhang concludes: “I would sumup System 3R’s operation in China likethis: Most people see the world as it is; wesee the world as it could be.
IMTS has always been a barometer used togauge the health and direction of NorthAmerican manufacturing. After what hasseemed like an eternity of bad news overthe last four years, the doors opened atIMTS 2004, with a sense that the cornerhad been turned and that there was nowhope for a return to positive growth in themachine tool industry.
If one were to go purely on the showstatistics (overall attendance and number ofleads generated) the outlook for the futurewould remain dim. However, the credo“Quality, not Quantity” was theunderlying theme, confirmed by the typeof interest and customers we welcomed toour booth.
No longer are companies sendingrepresentatives to Chicago for the nightlife.There was a ’business-only’ attitude forthose who attended. Their agenda wasclear: To seek out solutions to the problemsof maintaining quality while cutting costs.Here is where System 3R has and alwayswill offer solid solutions.
Delphin and WorkMaster are the starsTo quote Anders Utterstrom, one of theChicago-based salesmen, “Delphin was thestar of the show!” – a sentimententhusiastically endorsed by the rest of theSystem 3R team.
With a wide array of General Engineeringproducts taking half of the 160 sq.m.space, all levels of System 3R’s solutionswere on display. At the forefront was theintroduction of the first WorkMasterapplication supporting the Delphinplatform. This exciting addition to ouralready diverse WorkMaster repertoire willmost certainly become a large part offuture applications in this growing field.
Not to be outdone, the Die/Mould side ofthe booth attracted visitors who were
interested in seeing “what’s new” in bothdie-sink EDM and wire EDM. A secondWorkMaster, supporting a three-machinesimulation with WorkShopManager,allowed visitors to see that the capabilitiesand capacity of the WorkMaster productline continues to grow to support theincreasing role that automation must playif a shop is to remain profitable.
A toast to the futureConverging in the center of the booth,where Die/Mold and General Engineeringmeet, customers and prospects alikeenjoyed a quick drink and a snack in the“Combi Café”. Here is where the benefitsand advantages of System 3R’s solutionswere discussed at length.
As the show got ready to close, there was adefinite sense that, finally, the machine toolindustry was on solid ground and that itwas time for our industry to, once again,take control of its destiny. We at System3R are certainly prepared to contribute tothis rebirth and are presently following upon the projects that resulted from ourefforts at IMTS 2004.
Jonathan Zhang
System 3R China - Continued from front
World Round-upFrance
We had a verysuccessful attendanceat Micronora ,France’s majorexhibition for highprecision tooling.Over 50% of ournew project enquirieswere for metalcuttingapplications with a high proportion ofvisitors being very interested in our newVDP chucks. Customers now realise thatour exclusive VDP Technology opens up anew era in precision production. Improvedquality and productivity not only inexisting machine tools, but also for futureinvestment in 5-axis machines and High-Speed machining.
Germany
Full economicrecovery is still someway off, but we havebeen very encouragedby our sales growthand maintaining ourmarket share. Oursuccess in providinginnovative andpractical solutions, together with excellentcustomer relations and support will placeus in pole position for 2005.
Italy
The BIMU 2004exhibition in Milangave a clearindication that themarket situation inItaly is still stable.Some sectors such asaerospace, energy,medical andpackaging are stillinvesting in palletisation and automation,but other sectors are still suffering from
fierce competition from low-costeconomies. Our innovative solutions forimproved productivity are gaining moreand more recognition by our efforts toimprove the competitiveness of ourcustomers and we expect a measurablegrowth in sales during 2005.
Japan
The last decade ofthe 20th century isknown as ‘The LostTen Years’ in Japanand it still has amajor effect on oureconomy and onneighbouringcountries in S.E.Asia. Thegovernment’s ‘Quota’ system to protectmanufacturing industry has stimulatedsome resurgence in activity but there arecontinual pressures to become morecompetitive in the global economy,especially in relation to price and delivery.This is where our palletisation andautomation systems have been able to helpcustomers gain productivity benefits, notonly in EDM but also in metalcuttingapplications.
Switzerland
A 30%-plus increaseover last year inglobal orders forSwiss machine toolshas had a verypositive effect on ourOEM business.However, tool andmouldmakers are stillreluctant to initiatenew investment plans. Overall, automationprojects and our success in providingtooling solutions for precision engineeringhave shown significant growth.
Franck Cavalin(General Manager)
Peter Bilic(General Manager)
Mario Fornari(General Manager)
Koichi Saito(General Manager)
Niklaus Akermann(General Manager)
Our own automationinvestment adds
more muscle to theVällingby factory
System 3R USA’s successful stand at IMTS 2004
Shanghai – in many ways the symbol of the new China.
The Shanghai office
CONTINUED ON BACK PAGE...
SEE US AT A MAJOR EXHIBITION NEAR YOU!We are exhibiting at all the major worldwide exhibitions this year in order toshow you the very latest systems in improving productivity and in enhancingyour ‘bottom line’ performance.
We would also like to know if you do plan to visit us at these events and if youneed any tickets or other details, just let us know. We look forward to welcomingyou on the System 3R stand!
For more details please visit our Web Site www.system3r.com or contact yournearest 3R office.
3R IN ACTION
You can meet SYSTEM 3R at the following 2005 trade shows:
Major Japanese exhibitionheralds region’s recovery
The 22nd Japan International MachineTool Fair – JIMTOF 2004 – opened onan optimistic note, in line with forecasteconomic recovery. Demand for the ‘threesacred national treasures’ – flat screen TVs,DVD equipment and digital cameras – areexpected to continue to increase for at leastthe next 10 years; certainly for a longerperiod than the previous IT ‘explosion’.
Over 1,000 visitors registered their interestat the stand of System 3R Japan and theirprime motivator was ‘reduced costs andfaster delivery times’.
This theme was taken up by the majormachine tool builders who are nowfocused on offering their customers a ‘totalsolutions’ approach – to reducemanufacturing costs by increasing speeds,accuracy and efficiency of their machines.
With this in mind, 22 machine buildersincorporated System 3R products on atotal of 48 machines at the show, todemonstrate how these goals could beeasily achieved. The ability to integratehardware and System 3R productionplanning software – WorkShopManager,
for example – was also shown. Most of theleading machine builders have chosenSystem 3R as their ‘selected partner’.
Foremost among the products highlightedwere WorkMaster and WorkPal robots,including fully-automated production cellson the Charmilles, Matsuura and Yasdastands. System 3R products facilitating
24/7 unmanned/’lights out’production was also the mainfeature of the Makino stand.
System 3R tooling systemsdominated this sector of themarket at the exhibition and newproducts such as VDP andDelphin created great interest.These new highly robustproduction aids are especiallyimportant for the growingprecision production requirementsof maintaining high accuracy andstability under extreme conditionsof 5-axis and high speed machining
At the end of the exhibition,System 3R Japan were able to toast
the success of JIMTOF 2004 at their ‘3R-Day’ cocktail party, which saw the standoverflowing with machine tool builders,dealers and customers.
Production capacity atVällingby is being increasedto meet the ever-growingdemand for System 3Rproducts worldwide. For along time there has been aBlohm Profimat 307surface grinder, which hasbeen used to machine the“cross” in Macro referenceelements. This machinegrinder has now beenjoined by a Blohm Profimat MC407surface grinder and a WorkMaster with 90 magazine positions, each pallet carrying
nine workpieces.
The new machine does nothave a conventional worktable. The customarymagnetic table has beenreplaced by a 3Refix tablewith built-on dividing tableand a Macro chuck.
Production Manager, ThomasKarlsson, explains: “We nowhave a highly efficient double-
cell in which both machines are served bythe same WorkMaster robot. The oldermachine is totally dedicated to theunmanned production of the referenceelement 24-hours a day. We use the newmachine for manned grinding of “singlecrosses” – for example masters and levellingadapters – and then switch this machine tothe unmanned production of referenceelements for the remaining hours of theday. And it’s needed as orders are gettingbigger than ever before!”
A new, efficient wire EDM machine hasalso been installed – a Charmilles Robofil440cc – replacing two older wire EDMmachines. Soon, this machine will also beserved by a WorkMaster for unmannedround-the-clock production of holders andparts for vices in the System 3R productrange.
North America’s Machine Tool
industry is ready to take off
Thomas Karlsson, Production Manager
Koji Ishikawa, Chairman of the Board, retiresafter over 25 years with System 3R Japan
Our new double-cell served by WorkMaster
Kitty Tang
The busy System 3R stand at JIMTOF 2004
City Dates Title Stand No.
MARCH
HOUSTON, TEXAS, USA 1-3 HOUSTEX 308
CHEMNITZ, GERMANY 2-5 INTEC
APRIL
LOS ANGELES, 4-7 WESTEC 4015CARLIFORNIA, USA
TOKYO, JAPAN 19-22 INTERMOLD
BUDAPEST, HUNGARY 19-22 MACH-TECH
CHICAGO, ILLINOIS, USA 20-21 MOLDMAKING EXPO 1213
MAY
WEST SPRINGFIELD, 24-26 EASTTEC 1240MASSACHUSETTS, USA
SEPTEMBER
HANNOVER. GERMANY 14-21 EMO
MILWAUKEE, 27-29 WISCONSIN NMTE 1322WISCONSIN, USA
OCTOBER
PRAGUE, CZECH REPUBLIC 2-5 EURO PM 50
BRNO, CZECH REPUBLIC 3-7 MSV
TORONTO, 17-20 CANADIAN MTS 163ONTARIO CANADA
NAGOYA, JAPAN 19-22 MECT
NOVEMBER
FRANKFURT, GERMANY 30-03 December EUROMOLD
SYSTEM 3R IN ACTION AROUND THE WORLD
www.system3r.com
Productivity lights the wayAutopal s.r.o. of Novy Jicin, ineastern Czech Republic,established some 125 years ago
and currently employing 4000 people, hasbeen part of Visteon since April 2000. Theirmain products are headlight and rear lightclusters for the international automotiveindustry, exporting over 95 per cent ofproduction.
150 employees in the toolroom operate fiveCharmilles Roboform die-sink machines andtwo Robofil wire-EDM machines – all usingreference systems from System 3R –producing mould tools up to 12 tonnes.
The Macro system was introduced in 1987when a new die-sink machine was installedand in the last five years the MacoJuniorsystem has come to be used for more thanhalf of the graphite electrodes produced.
Pavel Chalupa, the engineeer responsible forthe toolroom, explains: “Autopal is focusedon productivity. Standardising on onereference system and palletisation are ourguiding principles. They not only allow us tomake more complex mould, but also ensurethat the user-friendliness of the Macro systemmakes life easier. Our customers demandever shorter lead times and we can’t affordexpensive scrap, nor to lose time or money.”
Because of this success, Autopal is nowconsidering the next step to remainingefficient and even more competitive – fullautomation. Today some 40 per cent of theirelectrode manufacture is sub-contracted so
the need to become self-sufficient is an addedincentive. They therefore plan to investmentin a WorkMaster robot serving a machiningcenter, producing an automatic productioncell which can run around-the-clock!
Innovative thinking gives
company a new lease of life
At the beginning of 2004,Giampietro Monaco had theopportunity to acquire Costat, a
plastics injection moulding company. It hadbeen in business for 20 years and like manycompanies in the Turin region, was a supplierto the automotive industry and therefore anideal fit with his own toolmaking business
But then he had to find someone capable torun the company and he actually approachedone of his competitors, Salvatore Rizzo,whom he had admired for some time. Rizzohad 30 years’ experience in the industry andhad achieved much with limited means andgreat commitment. So, a deal was struck.
“I saw this opportunity as a real challenge,”said Salvatore Rizzo. “I inherited 15experienced employees and an ample rangeof machines, all of which needed to run asefficiently as possible. I was convinced that inorder to succeed in this highly competitivesector you need to advance the operationfrom toolmaking to tool production. Youneed to minimise lead times, improve quality,minimise scrap and human errors. That’swhere automation is the answer!”
“But automation demands a uniformapproach to working. What I found werecompetent employees but majorshortcomings in systems thinking. Thestrategy was clear from the outset – step onewas to change the culture in the workshop byintroducing systems. Step two was toautomate.”
Lead times halved
Rizzo continues: “I haveyears of experience ofSystem 3R productsand their positiveeffects. Here, the
Macro system had been used in the die-sinking EDM machines, but the inherentbeneficial potential of integrating it as asystem was not being exploited.Standardisation and systemisation are nowkeywords in the workshop andimplementation has been relatively problem-free. Once people grasp the fundamental ideathey accept it right away. Everything is somuch simpler!”
Now Costat is using MacroJunior and Macrosystems in the die-sinking EDM machinesand in electrode manufacturing. The shapeand position of the electrodes weredetermined when the tool was beingdesigned using CADCAM. Two of themilling machines for machining the die setshave been fitted with the new Delphin zero-point system for fast, precise changes of theheavy workpieces.
The outcome of these investments, not somuch in products as in employee training,has been good. “Since the beginning of theyear, lead times for the mould tools havebeen broadly halved,” explains SalvatoreRizzo with pride.
Committed to full automation
So the foundation had been laid for the nextphase – full automation. A new high-speedmilling machine was installed for electrodemanufacture – a DMG 70 eVolution – in aproduction cell, served by a 32-positionWorkPal robot.
“It’s important to start at the right end whenintroducing automation,” says SalvatoreRizzo. “There’s no point investing in anautomatic EDM cell if you can’t feed it withenough electrodes.”
Initially this production cell was expected todeliver about 100 effective hours per week.Further down the line, two new CNCmilling machines are planned, as well as afurther automatic EDM cell.
Rizzo concludes: “Today we have one personper machine, but in the near future I hopethat one operator will be handling threefully-automated production cells. The
available machine capacityneeds to be utilised
efficiently round theclock, seven days
a week.
The Delphin system offers fast and precise set-up of mould bases in the milling machines.
Milling graphite electrodes in MacroJunior holdersThe Macro system at work in die-sink EDMoperation
A dynamic duo – Salvatore Rizzo (Left) and Giampietro Monaco.
“Remaining a top sub-contractorwas vital to our survival andfuture growth,” explained John
van der Laan, Managing Director of LandesFijnmechanische Industrie BV, located in thenorth of Holland.
“A significant dip in the market in 2002immediately stimulated us into takingpositive action so that we could remainstrongly competitive and well-placed whenthe market took an up-turn. We weren’tprepared to just wait and see, so we initiateda number of brain-storming sessions whichled us to some fundamental conclusionsabout efficiency and productivity.”
Up to that point in time Landes had workeda traditional shift system but this had in-builtinefficiencies especially when the shiftschanged. So a move towards automationseemed to provide the key to increasingmachine output in a given period of time.Especially as their customers – includingthose in laboratory and medical equipment,aerospace, textile machinery and generalengineering – increasingly demanded shorterlead times.
Because of the size of the products they weremachining, often in small productionquantities with varying cycle times,unmanned or low-manned production basedupon a pallet system seemed the answer.
Confidence in System 3R
Research into the marketplace quicklyestablished the way forward and Landesinvested in their first automated productioncell at the end of 2002. This comprised aDMU 50 eVolution machining centre plus aWorkMaster robot with a 41-positionmagazine.
“The preference for System 3R,” says van derLaan, “was based on technical evaluation andon their valuable experience and support thatthey could offer all the way through theautomation process. System 3R understoodprecisely what we wanted and gave us theconfidence that it could be achievedtechnically and organizationally.”
This initial set-up for full automation turnedout to be so positive that the first productioncell was quickly followed by a second one,but with a DMU 70 eVolution machine.
“Both production cells are cutting for 18 - 20out of 24 hours – in line with our mostoptimistic expectation. Compared to the oldshift system, it is a great improvement,”explains van der Laan. “The losses inmachining time from lengthy set-up timesevery product change meant we were onlypreviously getting about 40 per cent of thetime in production, if we were lucky!”
Five-axis machining
Now, one operator controls both productioncells during normal working hours. At theend of the day the cells are fully programmedfor unmanned operation throughout thenight by using WorkShopManager, System3R’s special production planning software.
Because of the type and size of products theymachine, care is taken to ensure that the
pallet capacity is used to its optimum forcontinuous production which may result inthe clamping of different parts to a singlepallet. Even then, if an operator is required toreset or reload the cell, an SMS text is sent tonotify him of its status.
5-axis machining for complex parts has alsobe come an important reality with theefficient clamping and accuracy features ofSystem 3R pallets. “Five-axis machining inone clamping is not only faster,” explains vander Laan, “but it also prevents inaccuraciesdue to the inverting of the metal or plasticworkpiece.”
Benefits all round
“The arrival of the two production cellsrequired some organisational changes. Theintroduction of new software always leads toadaptation. For many products new softwarehad to be written and two milling machineoperators have been retrained asprogrammers. The pressure on the workpreparation department has grown, withcustomers taking advantage of our ability tomeet even quicker deliveries. Tool supplymust be 100 per cent,” continued van derLaan.
“On the other hand, we have achievedimportant quality and productivityimprovements, and there is less scrap – allhelping improve our competitiveness. Lastbut by no means least, automation certainlydid not lead to forced resignations orreductions in staffing levels. On the contrary,we have recently engaged some newemployees!”
Landes have never looked back…
A charged companyIn 1995 a young man withinitiative left hisgovernment job
and, in the true spirit of freeenterprise, started a companyto manufacture rechargeablebatteries with basic premises anda handful of employees.
In 2003 this entrepreneur, WangChuan-fu, was rated one of China’s top tenbusinessmen. In only 8 years, his company,BYD, had grown into the world’s largestmanufacturer of mobile phone rechargeablebatteries with over 60% market share. It nowemploys around 30 000 people and hasoperations in several Chinese provinces, aswell as Japan, Korea, Europe and the USA.
So it’s quite likely that inside your mobilephone or your laptop you will find a BYDproduct - even if the brand name on theproduct is Nokia or Motorola, for example.
Row upon row upon row...
BYD’s injection mould tool making andmass production division is based inShenzhen, Guangdong province.
Wang Kai-feng, Moulding DepartmentSupervisor at Shenzhen, is proud of thetoolroom which has an enviable line-up ofmachines. 43 die-sinking EDM machines(Makino, Sodick, SKM), 8 wire EDMmachines (Charmilles, Fanuc, Sodick), 19CNC milling machines (DMG, Röders,Mazak, Mori Seiki) - with the Rödersmachines being used entirely forelectrode manufacture. And they needto be, since each tool requires around100 electrodes - half graphite; halfcopper.
Wang Kai-feng explains: “Here we
produce 120 mould tools a month with 80more at our Shanghai factory. We have beenin these premises for four years but inFebruary 2005 we are moving to new
premises, eight times the size. We need thespace as we expect to be producing 500
tools a month in a few years’ time.At the same time as the move,
we are installing 30 moredie-sinking EDM
machines and tenRöders CNC
millingmachines.”
The toolroomemploys 500 people - 380 of
these being operators or toolmakers- in threeshifts and with a high proportion of women.
Productivity doubled!
Jin Xu-li, Assistant Manager of ToolingDepartment is highly enthusiastic aboutSystem 3R: “We introduced the Macrosystem in February 2004 and although notall our machines have been fully equipped,the results have been excellent. Accuracy isnow twice as high. We can interrupt amachining operation to do an emergencyjob. Production costs have been reduced byone-third and productivity has doubled.We’re counting on System 3R meeting ourfuture needs.”
A look into the future?
Finally, we simply had to share with you anitem from Forbes Magazine:
In 2003, BYD acquired the Xian QinchuanAuto Company, which was producing20,000 cars a year. Now the cars are beingmade under the name BYD Auto, the firstprivately-owned carmaker in China.Admittedly, 20,000 cars is scarcely 0.5 % ofthe huge Chinese market, but even so…Possibly the world’s leading manufacturer ofrechargeable batteries combined withcarmaking - do you have a feeling somethingmight be going to happen?
The impressive CAD department
In order tocontinuegrowing,
NyproMold Inc. of Clinton,Massachusetts, required anew building and morecapital investment inequipment.
However, they wanted toremain in the town ofClinton since the majority oftheir employees lived nearby.The problem was that the only suitablelocation for a factory was already occupied bythe town’s baseball field. After somediscussion with the town’s officials, a mutualagreement was reached whereby NyproMoldwould build, at no cost to the town, a newand modern recreational facility at a differentlocation. In return, NyproMold would beable to build their factory on their selectedlocation.
Ghassan Aswad, Sales and MarketingCoordinator, explained that they brokeground for the new building in 2002, and ittook approximately one year to build.Moving in and setting up took six months,and they are now up and running. Visitors tothe 104,000 square foot plant can get anoverall view of the manufacturing area fromabove, through a “window wall” in the upperobservation deck.
Built for maximum efficiency
The principals of NyproMold, BillMuldoon and Brian Walker,understood several years ago that thefuture of mouldmaking was inautomation. Early discussions withSystem 3R, paved the way to theautomation principles applied byNyproMold today.
By walking the length of theobservation deck, it is apparent that the
different types of machine tools arestrategically located in specific groups formaximum efficiency. It is obvious that a great
deal of planning have been done to create anefficient manufacturing flow.
Ghassan Aswad explains: “20 die-sink EDMmachines are operated, half of which arecontrolled by WorkMaster robots and halfoperator-controlled. We also employ 10 wireEDMs, with two of them controlled by aWorkMaster, and the rest operator-controlled.
Producing and storing theelectrodes
Keeping 20 die-sink EDMs supplied withelectrodes for around-the-clock operation
requires highlyefficient machinetools and properproduction planning.High-speed millingmachines, such as theMakino SNC64equipped withrobotic loading andunloading, are usedto manufacture themajority of theelectrodes.
Cataloguing andstoring the electrodesis accomplished usinga “Hanel Lean-Lift”,
Bill Muldoon, Presidentof NyproMold.
Keep on running… and pedalling!
One of the world’s leadingmountain bike componentmanufacturers - Hope
Technology of Barnoldswick, Yorkshire – hasa constant need to gain productivity fromtheir existing machines. And that is whereSystem 3R stepped in by providing an easyand effective solution with the WorkPalCompact pallet changing robot.
Even though their FanucRobodrill 3-axis verticalmachining centre camewith a single pallet, theinefficiency of manualloading small bikecomponents such as brake levers and brakecylinder caps was a problem.
“We were already using efficient palletchanging on our Matsuura MAM machiningcentre so automation was the obvioussolution,” explained Simon Sharp, Directorof Hope Technology. “What we wereconcerned about was the retro-fit of a robotto an existing machine, but after looking atthe major players we selected the WorkPalCompact and have been totally satisfied withits performance.”
90% of components are aluminium andsmall so it was important that the maximumnumber of parts could be loaded at any onetime. System 3R GPS 240 pallets (size 240 x240 mm) therefore ensured that machinecapacity was optimised with 6 pallets, which
are lightweight yet robust, further aiding theloading of the machine. The 0.002 mmaccuracy of the system is also an addedbenefit which enhances the ISO9002Quality Control Accreditation of which thecompany is proud.
The WorkPal Compact is what it says – with
its small footprint a boon in the convertedcotton mill that is Hope Technology’s busyplant. Installing the robot alongside theRobodrill was easily achieved. The rotaryindexing magazine makes it easy for therobot arm to select a pallet and load iteffortlessly through the automated slidingdoor onto the machine table.
Brake levers are machined 8 parts to a palletand cylinder caps 20 parts per pallet, withdifferent cycle times per part, so the WorkPalCompact allows for these variations andproduction is seamless. The clamping ofparts to the pallets is also easy and robust.
“We have achieved what we set out to dowith the WorkPal Compact. We have gainedextra hours and extra production. It deliversunmanned running during shift breaks, afterhours and, especially, while loading, withoutstopping the machine,” continued SimonSharp. “We are very pleased with itsperformance and the significant increased inmachine utilisation and productivity!”
Established in 1987, Hope Technology is aleading name in the world of mountainbiking, working at the cutting edge ofengineering technology. The companycurrently employs over 60 people inmanufacturing and design, exporting to over30 countries. They are innovators in brakingtechnology, including the introduction ofdisc brakes on bikes, as well as providing awide range of other quality components -hubs, headsets, fork guides, seat clamps,skewers, stems and lights.
Car light cluster
NyproMold leads the way to the future of mouldmaking
that is centrally located on the shop floor,and is controlled from an inventory accesspanel. Any group of electrodes can quicklybe delivered to the Lean-Lift’s access door forimmediate use. This tower-type unit storesand protects thousands of finished electrodesfrom damage, while taking up very little floorspace.
A concept comes alive
The die-sink EDMs are used to producevirtually all the mould cavities required.Once the electrodes and workpieces havebeen loaded into the racks and the EDMmachine is programmed, an operator is nolonger needed. The WorkMaster
Producing62% of theworld’s mobilephone batteries
Two Yasda miilling machines work in tandem with the aid of a WorkMaster.The mill is shown machining steel components of the injection moulds.
A tray of electrodes at the access station of theLean-Lift is ready for transport and loading intothe storage rack of a die-sink EDM cell
accomplishes the loading, unloading andreplacing the finished parts in the rack.When the last part is completed, it signalsthat the batch is complete.
When you watch a number of differentmachine tools, all being tended to by System3R WorkMasters, the reality of “around-the-clock-manufacturing” hits home. It is a lookinto the future of mouldmaking.
Dual “drop tank” Ingersoll die-sink EDM machinesare working around-the-clock, while being loadedand unloaded by a WorkMaster
DMU 70 eVolution with WorkMaster and magazineon the right-hand side
Managing Director, John van der Laan: “We’vegained increased productivity and there is lessscrap – both aspects lowering costs and henceimproving our competitiveness.”
The 41-position magazine fully-loaded withpalletised workpieces
Simon Sharp is impressed with the WorkPal’sperformance
Wang Kai-feng the proud Moulding DepartmentSupervisor
