perspectives from an overall system supplier - vogelfile.vogel.com.cn/2014/1111/1412094883.pdf ·...
TRANSCRIPT
Future of the
Automotive Aggregate
Production
Perspectives from an
Overall System Supplier
Dr. Heiner Lang
President Europe & Asia Pacific
MAG IAS GmbH
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Summary 4
Future of Aggregate Production System 3
Characteristics and Future Challenges in the Automotive Powertrain Production 2
Introduction of MAG 1
Agenda
2
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014 3
MAG focuses today on the automotive business
MAG IAS GmbH today
Employees: 1,038 (2014) Locations/ sites: 7 Products: 25 Customer base: ~100 (only Automotive) Revenue: ~500 mio. €
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
MAG Automotive Group At a glance
4
Solution provider: individual
manufacturing and technology
solutions as well as service & retrofit
Market development and proximity
to our customers:
- 15 production, sales and service
locations worldwide
- thereof 7 production plants in Europe,
the Americas and Asia
Eislingen/Fils, GER
Goeppingen, GER
Rottenburg, GER
Birmingham, GBR
Neuhausen a. Rhf., SUI
Kecskemét, HUN
Sterling Heights, MI
Port Huron, MI
Changchun, CHN
Beijing, CHN
Shanghai, CHN
New Delhi, IND
Pune, IND
Bangalore, IND
Chennai, IND
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014 5
MAG Automotive Group Global references (excerpt)
North America
Silao, Puebla (MEX)
Lima, Livonia, Romeo, Sharonville, Van Dyke,
Dearborn, Windsor, Cleveland, Sterling (USA)
Essex (CAN)
Chihuahua (MEX)
Detroit, Warren, Tonawanda (USA)
St. Catharines (CAN)
Ramos Arizpe, Coahuila, Toluca (MEX)
Decatur, Lafayette,
Mossville (USA)
Nashville (USA)
Guelph (USA)
Ramos Arizpe (MEX)
Columbus, Lakewood ,
Jamestown (USA)
Kokomo, Trenton (USA)
Dickson, Glasgow (USA)
Saltillo, Coahuila, García (MEX)
South and Central America
Taubaté (BRA)
Europe
Asia
South-East Asia
Jamshedpur (IND)
Chengalpattu (IND)
Port Elisabeth (RSA)
Geelong (AUS)
Chennai (IND) Chennai (IND)
Pune (IND)
Chennai (IND)
Gurgaon (IND)
Pune (IND)
Haryana
(IND)
Liuzhou,
Qingdao
(CN)
Chongqing,
Harbin (CN)
Chongqing (CN) Beijing (CN)
Shenyang (CN)
Dalian,
Changchun
(CN)
Changchun (CN) Beijing (CN)
Shanghai (CN)
Boading (CN)
Shanghai (CN)
Ningwei (CN)
Wuhu (CN)
Shenzhen (CN)
Beijing (CN)
Chungbuk (KR)
Changwon-Si (KR)
Wuhan (CN)
Shanghai (CN)
Yantai (CN)
Whitley (GB)
Stuttgart, Kölleda, Esslingen,
Mannheim, Gaggenau (GER)
Rüsselsheim (GER)
Szentgotthárd (HUN) Dagenham, Basildon, Bridgend,
Brentwood (GB)
Craiova (RO)
Elabuga (RUS)
Blanquefort Cedex (FRA)
Köln (GER)
Valencia (ESP)
Ingolstadt (GER)
Györ (HUN)
Salzgitter, Chemnitz,
Baunatal, Braunschweig,
Wolfsburg (GER)
Kaluga (RUS)
München, Berlin
Dingolfing (GER)
Steyr (AUT)
Södertalje (SWE)
Mladá Boleslav (CZ)
Skövde,
Göteborg (SWE)
Liverpool (GB)
Köln (SWE)
Togliatti (RUS)
Jaroslavl,
Nizhny Novgorod
(RUS)
Nabereschnye
Tschelny (RUS)
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Summary 4
Future of Aggregate Production System 3
Characteristics and Future Challenges in the Automotive Powertrain Production 2
Introduction of MAG 1
Agenda
6
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Higher product
variances/shorter
development cycles
Environmental and
ergonomical requirements/
emission constraints
of production and product
Machines inform
about status
Challenges for OEM car manufacturers and
Machine Tool Industry for Automotive
7
Small batch sizes/
higher flexibility/
reconfigurability
Efficient production/
new technologies for
better product
characteristics
Total connectivity
hardware software
1950s 2020
Software/electrification are the dominating skill factors for modern machines
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
customer behavior Future trends in customer requirements
8
Costs The trend is towards low cost solutions for
roughing and pre-machinery. New machine
tool manufacturers edge into the market
with dumping prices.
OEMs are looking for alternative solutions
(Daimler, VW)
Productivity and Quality
Two orientations (depending on OEM) Standard solutions, low innovations,
solid production
High technology, increased output,
less investment, environmental
aspects
Quality requirements are growing)
Flexibility
CO2 reduction is the driving criterion
for new products and variants
(retooling required)
Energy and resource efficiency at the
production: machines, tools, coolant
Environment and ergonomy
Prio 1 is flexibility regarding to engine
types and variants (engine versions)
Flexibility in output is almost as
important as react to fluctuating
production requirements
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Summary 4
Software Solutions 3.3
Process Technology 3.2
Machine Tool 3.1
Future of Aggregate Production System 3
Characteristics and Future Challenges in the Automotive Powertrain Production 2
Introduction of MAG 1
Agenda
9
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Technology
Competence
Dry cutting
Cryogenic
Honing
Hardfine
machining
Spray coating
Machine
Competence
Modular building
blocks
Platform design
Key components
Retrofit capability
Energy saving
Overall System
Competence
Turn-key capability
and application
know-how
Scalable systems/
customized layout
Reconfigurable
Software
Competence
Work order tracking
eLearning for MAG
products
Condition
motitoring
Material flow
simulation
Sustainable Manufacturing on 4 sucess columns
10
Develop outstanding company reputation on
core competences, technological excellence and competitive pricing Mission
Sucess
columns
Guiding
principles
Focus on customer relationship with honesty, integritiy and trust
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Summary 4
Software Solutions 3.3
Process Technology 3.2
Machine Tool 3.1
Future of Aggregate Production System 3
Characteristics and Future Challenges in the Automotive Powertrain Production 2
Introduction of MAG 1
Agenda
11
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
MAG‘s Machine Competence and USP‘s
12 12
Productivity Quality
Flexibility Environment & Ergonomics
High machine rigidity and
dynamics in the market
=> full developed range
Energy efficiency packages
and hydraulic free machine
=> Comply with „green“
requirements
Modular machine design
=> Configuration based on
standard building blocks
Key components based on
MAG production
=>in house core
competency
Designed for efficient
service and maintenance
=> Short repair times
Maschinen Technologie
Retrofit experience
=> Support customer with
Modernization of existing
manufacturing systems
Ready for dry, wet and
cryogenic machining
=> All customer needs
supported
TCO/OEE:
=> Economic production
Only on
MAG
machines
MAG
Patent
MAG machines are benchmark in terms of innovations, productivity, and OEE
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Energy Efficiency Savings
Example: machine with energy saving package
13
PRODUCTION WAITING ON PARTS
-49%
-27%
Lifting pump
Fan
Chip conveyor
Hydraulics
24V
Chilled water pump
Ventilation
Coolant HP pump
Drives
5,4
10,6 10,5
14,3
Standard with energy packet Standard with energy packet SPECHT 600 DUO
Energy package with significant savings by means of hardware and software
Application for Mobile Devices
Energy Monitor for HMI at Machine
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Summary 4
Software Solutions 3.3
Process Technology 3.2
Machine Tool 3.1
Future of Aggregate Production System 3
Characteristics and Future Challenges in the Automotive Powertrain Production 2
Introduction of MAG 1
Agenda
14
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
MAG‘s Technology Competence and USP’s
15 15
Productivity
Environment & Ergonomics
Dry cutting (min. lubrication)
=> increased cutting speed
=> decreased cost
Cryogenic (liquid nitrogen)
=> faster machining
=> less tool wear
Adapter plate systems
=> Work piece flexibility
Machining in one clamping
=> High product quality
=> Less machines
Temperature compensation
=> Eliminate environmental
impact
Spray Coating + Honing
=> improved end-product
Performance (CO2 red.)
Hard fine finishing
=> substitute expensive
grinding process
In process compensation
=> Less scrap parts
MAG
Patent
Only on
MAG
machines
MAG
Patent
Quality
MAG
Patent
Flexibility
MAG
Patent
MAG develops unique solutions for today‘s and future demands on technology
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Cutting 1.4024 martensitic steel
16
INSERT 1
1.4024 steel (40 HRC)
90 mm milling head, 5 edges
Cutting Speed190 m/min, infeed 1,5 mm
60% increase in productivity
Fre
e s
urf
ac
e w
ear
[in
]
material removal [in³]
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Summary 4
Software Solutions 3.3
Process Technology 3.2
Machine Tool 3.1
Future of Aggregate Production System 3
Characteristics and Future Challenges in the Automotive Powertrain Production 2
Introduction of MAG 1
Agenda
17
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
USP‘s in Software Competence
18
Integrating Shop Floor to Top Floor
Total integration into all production-relevant
software packages
e.g. SAP ERP
Provision of suitable information at all
business levels
x x =
Availability Performance Quality OEE
Customer
valued
USP
x x =
Customer
valued
USP
Machine tool
via
MAG Software
+ external data
(e.g. Spread
Sheet or ERP)
+ external data
(from worker
or measuring
machine)
MAG solutions
for measuring
the categories
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014 19
Vision Industry 4.0 @ MAG
Customer
Cloud
(optional)
MAG
Service
Support Spare Parts
R&D
New Concepts Adjusted
Components
Proposal
TCO
Submitted data generates value-add on both sides
Industry 4.0 enables complete communication and integration
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Summary 4
Future of Aggregate Production System 3
Characteristics and Future Challenges in the Automotive Powertrain Production 2
Introduction of MAG 1
Agenda
20
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014 21
Summary
MAG Energy Package
- Energy monitor
- Start-stop-automatic
- Energy efficient components
25 % reduction (7.500 €/year)
Investment 15.000 €
MAG Process Technology
- Shorter processes
- New technologies
10 - 15 % less investment
5 – 8 % cost per part reduction
MAG MQL Technology
- Less components per unit
- Lower running and maintenance cost
Up to 15 % lower investment
7 % lower part piece cost
30 % less energy consumption
MAG Ergonomics and Training
- e-learning and trouble shooting
- New maintenance guide
- More productivity
Approx. 10 % more production
Investment 50.000 €/system
MAG Hydraulic Free Machine
- Electro mecanical actuators
- Less maintenance (filter, refill)
- Higher reliability
4 % less life-cycle-cost
Dr. Heiner Lang Future of the Automotive Aggregate Production 23/10/2014
Thank you for your attention
22