DMG MORI advances MX strategy (Part 1) – The first step is process integration

DMG MORI is driving forward its “Machining Transformation (MX)” strategy. MX encompasses a series of solutions including process integration, automation, digital transformation (DX) and green transformation (GX). On April 17, DMG MORI held a press conference at its Iga Campus in Mie, Japan, to explain its MX strategy and other initiatives. The first step of MX is process integration, and this article focuses on examples of process integration within their own factories. 

Process Integration, automation and DX to achieve GX

Katsuhisa Shimokawa, Managing Executive Officer and Iga Campus Chief, spoke about the concept of MX, stating, “We are achieving GX through process integration, automation, and DX.” 

While GX is often associated with decarbonization and energy efficiency measures, Shimokawa explained, “Our GX involves creating lean and clean factories in every aspect: people, resources, energy, space, and lead time.” 

Process integration: The first step in the MX strategy 

The first step in the MX strategy is process integration. By introducing 5-axis machining centers and multitasking machines, DMG MORI aims to shorten the entire production line while reducing the resources required for machining. The next step is to use automation technologies to build a production system that does not rely on manual labor, thereby achieving GX. DX technologies have been utilized to accurately and quickly implement process integration and automation technologies in the production line.

Introducing super-large 5-axis MCs in the new factory 

The “DMU 1000 SE” introduced in the No.3 Precise Processing Plant

The company has been positioning its factories as showrooms where customers can experience the MX strategy firsthand. 

A highlight of the recent press conference was the unveiling of the new “Iga No.3 Precise Processing Plant,” a facility focused on process integration. This facility machines large cast iron components such as beds and columns. With a total floor area of approximately 5,600 square meters, the plant became operational in May of this year. 

Previously, large cast iron components were machined on five large 5-axis machining centers and four large grinding machines. These have been replaced by three in-house produced “DMU 1000 SE” ultra-large 5-axis machining centers to achieve process integration and improved productivity. Two of these machines are already operational and a DMU 1000 SE grinding specification will be introduced by next year. The total investment for the building and the three machines amounts to approximately 5.5 billion yen. 

The ball screw processing cell with integrated process integration and automation

The DMU 1000 SE, manufactured at the Pfronten Plant in Germany, is an ultra-large 5-axis machining center. It features high-capacity spindles and a full-coverage structure that reduces non-productive time and improves machining conditions. 

In addition, the existing “No.2 Precise Processing Plant” incorporates process integration and automation technologies in the ball screw machining cell. Five multitasking machines efficiently process screw shafts, square nuts and flange nuts, while the transportation of these workpieces is automated by the in-house developed “WH-AMR10” autonomous mobile robot. 

“Previously, screw shaft machining was divided into five processes, but we integrated them into a single multitasking machine, reducing the lead time from four days to 80 minutes,” explained Shimokawa. 

By: Atsushi Kuwasaki
Staff Editor, SEISANZAI Japan