DMG Mori: Breakthrough setting in metalworking field (Part 1)

DMG Mori headquartered in Bielefeld is a leading German enterprise in the field of metalworking. Currently, the company supplies high quality machine tools and machining centers to many countries around the world such as Japan, Korea, Canada, India and the United Kingdom.

Known as an automation equipment and service provider, DMG Mori has brought success to many businesses around the world by making a breakthrough in their processes.

One of the proudest achievements of DMG Mori is to help Eisenwerk Erla GmbH – a manufacturer with a lifetime of up to 600 years, successfully convert an outdated production system into a 99% automated system and Achieve quality productivity results immediately.

Eisenwerk Erla is currently a partner of many automotive giants such as Audi, BMW, Daimler and VW, as well as suppliers such as IHI and BorgWarner. Therefore, improving service quality and product quality is always a burden on the company. Especially in 2015, some package orders were not received due to limitations of the production line of turbine housings, exhaust pipes, manifolds and engine mounting racks.

To solve this problem, the company management has transformed the foundry and machining in the Saxon town of Schwarzenberg to digitize, automate with the goal of reducing labor costs, improving productivity and meeting better response to customer requirements.

In the automatic line, the machining centers are linked together to create a “turnkey” response chain, including commands that are set up on a computer. The customer’s request is considered a necessary and sufficient condition, and the method of implementation is entirely determined by the operator. These members are temporarily transferred from different functional departments and they are still under the management of the functional department but take on their professional part in the production process.

In this way Eisenwerk Erla only needs to hire 18 skilled staff to run their 17 production shifts. DMG Mori setup consultant Rico Klotz was involved in setting up the mechanical work from the very beginning and teaching the company the basics. “Our aim is to make manufacturing as simple as possible for all employees to minimize the risk of errors.” Therefore, every finishing step is checked for accuracy according to special criteria. “We use the same equipment for periodic checks in the metering department and standardized shipping boxes so that the robot can disassemble components during assembly and immediate installation.”

(To be continued)

Productivity and Quality Office