Perspectives from an Overall System Supplier · Pune, IND Bangalore, IND Chennai, IND ......

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. €


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


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)


Summary 4




Agenda

6


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


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


Summary 4

Software Solutions 3.3

Process Technology 3.2

Machine Tool 3.1




Agenda

9


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


Summary 4



Machine Tool 3.1




Agenda

11


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


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


Summary 4



Machine Tool 3.1




Agenda

14


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


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]


Summary 4



Machine Tool 3.1




Agenda

17


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


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


Summary 4




Agenda

20


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


Thank you for your attention

22

Perspectives from an Overall System Supplier · Pune, IND Bangalore, IND Chennai, IND ......

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