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The Fully Automated Production Line

The Fully Automated Production Line

Pre-process, cut, transport, and sort sheet metal parts according to orders. All this is carried out by the fully automated Production Line. Bystronic is thus presenting a solution for sheet metal processing in the age of automation and digital networking.

The fully automated Production Line revolves around the ByStar Fiber laser cutting system and integrated automation solutions from Bystronic. The digital Shop Floor Control System integrates the Production Line into the existing sheet metal production environment. This guidance system enables users to set up a manufacturing landscape around the Production Line that permits all sheet metal processing steps to be seamlessly integrated.

The Production Line is capable of processing sheet metal parts both in large series and on a small scale. The integrated laser cutting and automation technologies adapt flexibly to changing order situations while also enabling customised expansion with modular options. The idea behind this manufacturing concept is to combine versatility and productivity. Both are important requirements for industrial sheet metal processing.

Bystronic recently showcased a solution that in the near future will enable the Production Line to be expanded to enable the pre-processing cut parts. ByFlex, an additionally integratable system, drills and deburrs holes, and cuts threads, if required even with countersinks, in sheet metal parts prior to the laser cutting process. The integration of this solution, even before the actual laser cutting process, allows users to make optimum use of secondary processing time within the Production Line.

ByTrans Cross And BySort In The 4020 Format

The objective of automation in the field of laser cutting is to make it possible to process not only large series but also small batch sizes, while maintaining the flexibility that users require to always respond to changing order situations. Bystronic offers the ByTrans Cross automation solution and the BySort module in the 4020 format. This provides users with an extremely versatile extension for the ByStar Fiber 4020 laser cutting system. The ByTrans Cross handles the entire loading and unloading process on the shuttle table of the fibre laser cutting system. This enables metal sheets of up to 4m by 2m to be handled.

As an upgrade module for ByTrans Cross, BySort expands the sorting process for finished cut sheet metal parts with a weight of up to 100 kg. What makes this solution so special: BySort enhances the range of functions in the automated unloading process without requiring the user to expand the footprint of the ByTrans Cross.

Due to the extremely fast throughput times of the ByStar Fiber laser cutting system, with an output of up to 10 kW, automated material loading and unloading is virtually a must, explained Product Manager Alain Meyer. Users can only fully exploit the potential of the fibre laser technology if the material flow is perfectly matched to the laser cutting system’s throughput times.

An additional aspect is the reduction of the machine operators’ workload and the associated increase in process reliability. The loading of raw sheets and the removal of residual grids in the 4020 format is difficult to carry out manually. Here, automation ensures safety and simple workflows. Mr Meyer also emphasised another benefit, “Automation enables users to utilise their laser cutting capacities efficiently around the clock with little manpower, even when faced with high order volumes and short delivery times. The increased autonomy thus also makes it possible to work lightly-manned night shifts.”

Flexibility For Varying Order Situations

The modular design of the ByTrans Cross means that the BySort upgrade can be retrofitted as a sorting solution at any time. For this, Bystronic expands the existing ByTrans Cross system with a bridge on which two sorting heads can operate. Both heads automatically equip themselves with a selection of gripper modules. Depending on the sizes and geometries of the sheet metal parts that are to be processed, the user puts together the matching magazine of grippers.

BySort removes finished parts, sorts them by order, and deposits them on various unloading positions next to the laser cutting system. Mr Meyer explained, “Depending on the production environment, BySort can stack finished cut parts on trolleys, pallets, conveyor belts, or even autonomous transport vehicles.”

This diversity in the unloading process supports sheet metal processing companies that are faced with the challenge of adapting to changing batch sizes. It also helps users to automate the production of small batches so that a variety of downstream processes, such as bending, welding, or painting, can be integrated as easily as possible with laser cutting.

For example, when parts are positioned on a pallet with high precision, they can be processed more easily in the bending step, because the robotics used here or the operator no longer have to check them and adjust them to the correct position. “The precision with which BySort stacks the parts translates into accurate gripping and error-free bending in the next processing step,” said Mr Meyer.

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Bystronic “TiltPrevention” Solution Optimises Laser Cutting Processes

Bystronic “TiltPrevention” Solution Optimises Laser Cutting Processes

With the “TiltPrevention” assistant function, Bystronic is increasing process reliability in the field of laser cutting. The intelligent function enables users to create cutting sequences that minimise the risk of creating protruding parts in the sheet. This reduces the disruption of cutting processes and downtime caused by cutting head collisions.

Tilted parts are a risk factor during the laser cutting process. They can cause a collision with the cutting head. This results in the disruption of cutting jobs, rejected parts, and in the worst case, costly damage. However, they also impede automated unloading, as the automation system’s grippers have difficulty picking up tilted parts.

Until now, micro-tabs have been a time-intensive method of preventing cut-out parts from tilting. The software positions small connections between the contour of the part that is to be cut and the residual grid in the cutting plan. In this way, parts remain fixed to the surrounding sheet after cutting. One disadvantage of this solution is: The cut parts require reworking in order to remove the traces of the micro-tabs. Another disadvantage: The automated removal of the finished parts is impeded because the micro-tabs make it difficult to remove the parts from the residual sheet.

Another approach is to use software to guide the paths of the cutting head during the cutting process so that, as far as possible, it circumvents risky sections where parts could tilt. However, this solution does not eliminate the root of the problem—parts protrude, still represent a risk, and are difficult for automation systems to cope with.

Algorithm Generates The Ideal Cutting Sequence

With “TiltPrevention”, Bystronic has now developed a new solution. In future, BySoft 7 will use this intelligent assistant function to compile cutting plans in such a manner that parts cannot tilt during the cutting process. This largely eliminates the need for micro-tabs.

How does it work? An algorithm calculates the mechanical behavior of the parts while they are being cut out of the sheet. To achieve this, “TiltPrevention” takes into account a wide range of parameters:  What is the density of the material that is being cut? What is the geometry and weight of the parts that are to be cut? How high is the pressure of the gas that flows out of the cutting head during laser cutting and exerts pressure on the parts? How are the parts positioned on the cutting grate? Are there enough contact points?

Subsequently, “TiltPrevention” recommends lead-in and lead-out points of the laser so that tilting of the parts after cutting is prevented to the greatest possible extent. In addition, the function proposes the best possible route for the cutting head over the metal sheet. This creates an ideal cutting sequence for all parts on the cutting plan. Cutting in such a manner that the cutting head never travels over parts that have already been cut out.

Regardless of the users’ level of experience, “TiltPrevention” supports them with an ideal cutting strategy that can be automatically incorporated into the cutting plan. Users can carry out customised adaptations at any time using the simulation created by “TiltPrevention” —modify the nesting of parts, reposition the lead-in and lead-out points of the parts, and add micro-tabs where required.

 

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Market Outlook 2019: An Insight Into This Year’s Industry Megatrends

Market Outlook 2019: An Insight Into This Year’s Industry Megatrends

In 2018, we witnessed the rise of Southeast Asia’s manufacturing industry as the Trade War pressured manufacturers into shifting production from China to Southeast Asia. A trend that is expected to continue on in 2019 as Southeast Asia continues to develop its manufacturing capabilities and uncertainties over a US-China truce continue to loom. Through this market outlook series, eight industry leaders share their thoughts on how the regional market will grow and develop in 2019 amidst the changing economic background and the increased presence of disruptive and intelligent technologies. 

  

Armin Kasper

Vice President, Asia-Pacific Area, MAPAL

2018 was a successful year for MAPAL and the company grew once again although growth in the Chinese market, which had previously been strong, flattened somewhat in the last quarter of 2018 due to factors such as punitive tariffs. For 2019, we have set a goal of generating a turnover of €650 million, and this will be achieved through free trade, the development of country specific expansions, the enhancement of digital capabilities and electric mobility machining capabilities.

Development Of Country Specific Expansions

For the companies under MAPAL Group in Southeast Asia, two new regional branches will be established in Indonesia where we are seeking to build a regional presence. While in the case of Malaysia, the country recently became our Southeast Asia production hub and has been equipped with a dedicated manufacturing facility. Additionally, we are actively investing in Malaysia and expansion is set to continue in Thailand too, where a new facility was established in 2017.

Enhancement Of Digital Capabilities

Digitalisation is a pressing issue globally, and in the face of increasing demands for efficient data management systems, we have identified this trend as a potential growth area. That was why we will be using 2019 to make further refinements to c-Com and to showcase the SaaS solution to interested parties as an open cloud platform for efficient data management.

MAPAL’s new tool management 4.0 is also based on c-Com. The interconnectivity that tool management 4.0 offers means that data can be provided consistently to all those involved – manufacturing, procurement, planning, tool managers and suppliers. That makes the overall process more efficient and digitalises tool management.

We also see great potential in our re-tooling service. Customers use this when they are setting up a new manufacturing facility for a part or re-tooling existing machinery to manufacture a new part, or when optimisations need to be made while production is running.

Electric Mobility Machining Capabilities

Alongside digitalisation, another significant trend at the moment is electric mobility and we have a diverse array of innovative machining solutions available for manufacturing the various parts within the different electric drives. The importance of the automotive industry is growing all the time, as is the number of vehicles being produced with electric drives.

 

Carsten Haecker

Head of igus Asia Pacific, igus Singapore Pte Ltd

The Asia Pacific region will remain as the growth driver for us in 2019 but we may see regional differences in development. This is due to uncertainties related to tariffs and trade, Brexit discussions and regional tensions may cause some interruption on a global scale. However, in terms of long term sustainability, the opportunities in Asia far outweigh the challenges and we will continue to invest into new markets or expand existing manufacturing facilities.

Combining Digitalisation With Industrial Development

The world is changing faster than ever before, new trends are coming up and past solutions may disappear. Artificial intelligence, complete process automation, remote monitoring of machine performance, intelligent robotics and driverless vehicles are some of the trends in which we see a potential in. The clear objective for us moving forward is to concretely implement automated processes that range from online configuration to digitally supported manufacturing for all product categories. This is a difficult path to take because ready-made solutions usually cannot be bought but have to be developed individually.

Additionally, IoT continues to drive development. And igus as an early adopter, has developed the intelligent cable, energy chain and linear guide which are able to monitor their own condition during use and open up new possibilities of predictive maintenance.

Additive Manufacturing And Low Cost Robotics

Additive manufacturing would be another key trend to mention, with 3D or SLS printing being good examples of the technology. Also, low cost robotics are another trend to watch out for in 2019 and the igus robolink modular robotic system is an example of this.

 

Israel Gonzalez

Asia Pacific Regional Director, Hypertherm

2018 marked Hypertherm’s 50th year and we have grown from a manufacturer of plasma systems to a global provider of cutting solutions. Moving forward, our continued investment in research and development is part of our efforts to bring more breakthrough technologies to the market, such as the recently released X-definition class plasma system.

In 2019, Asia Pacific will continue to be a promising region for the industry due to rapid population and economic growth, industrialization and business-friendly measures introduced by governments. Besides the major markets in Oceania and Japan, the rapidly growing industrial manufacturing sector in India and Southeast Asia are also expected to contribute significantly to the region’s economic growth.

Change In Business Models In The Metal Cutting Industry

The metal cutting industry will shift from a demand driven model to a more competition driven model, where the key driver is automation and customers are increasingly looking to reduce reliance on labour. In fact, automation will continue to be the biggest development in the metal cutting industry as manufacturers in the region continue to balance technology with capacity and competitive demands.

Industry 4.0 Innovations

IIoT will continue to shape the manufacturing industry in 2019. Rising technologies such as machines, robots and other equipment on a production floor will be able to communicate with each other and gather data in the cloud for analysis. And with the data, a manufacturer will have greater insights which allows for predictive analysis to occur. This aligns to the shift in the industry from preventive maintenance to predictive maintenance.

In the future, fluctuating raw material prices will also impact the industry and transformations within the manufacturing sector will also be further propelled by the rapid evolution of technology. To achieve growth targets in the coming year, manufacturers will increasingly see the need to prioritize investments in technology that will enable them to improve their business agility.

 

Terence Oh

Senior Vice President. EOS, Singapore

The additive manufacturing (AM) market is set to grow at a compound annual growth rate (CAGR) of around 27 percent between 2018 (USD 1.73 billion) and 2023 (USD 5.66 billion). In fact, AM in Asia Pacific is expected to have the highest CAGR due to the region having the fastest growth for the automotive and printed electronics sectors. This offers more opportunities for AM adoption in the manufacturing industry.

Decentralised, Distributed And Domestic Manufacturing Models

Rising protectionism and trade conflicts will increasingly push global supply chains towards decentralization and regionalization when it comes to manufacturing. And this, coupled with the digitalization of manufacturing and AM will serve as an enabler for distributed manufacturing. Businesses that adopt smart technologies like AM to 3D print parts and components will also be able to reduce production costs, processes, and time through part redesign and integration. This makes domestic manufacturing more practical than importing from abroad.

Continued Innovation And Adoption Of AM Across Industries

AM is reported to have a global economic impact of USD 250 billion by 2025 and the aerospace and defense industry is expected to continue leading AM adoption. Moreover, the global aerospace AM market is reportedly expected to register a CAGR close to 22.3 percent during the forecast period of 2018 to 2023.

In terms of the healthcare industry, AM adoption is expected to increase and with the aging population expected to rise, this trend is set to continue due to an expected increase in demand for personalized healthcare and treatments, as well as customized 3D-printed medical devices. For the automotive industry, AM’s ability to decrease production lead time, increase efficiency in logistics management, and ensure effective use of components/materials will result in its increased adoption. This trend is set to continue and the global automotive 3D printing market is predicted to be valued at over USD 8 billion by 2024. On the other hand, tooling and robotics are also expected to drive AM’s market share in APAC from 2018 to 2023.

 

Douglas Foo

President, Singapore Manufacturing Federation

The manufacturing industry in Asia is polarised into three categories – the “factories of the world”, the factories supplying to “factories of the world”, and the “middleman”, where most manufacturers in Asia are a part of. In Singapore, the industry is undergoing a two-part transformation – digitalisation and servitisation.

Due to Singapore’s relatively high labour cost compared to the region and talent shortage, the industry is also moving up the value chain and exploring the use of AI, IoT, robotics, automation and other digital tools to keep costs low and to increase productivity. Digitalisation itself is expected to quite significantly alter and remake the landscape of the industry.

Digitalisation Of Manufacturing And Supply Chains

To be digitalised is to implement these few technologies – additive manufacturing, AI, advanced manufacturing, blockchain, cloud computing, big data, e-commerce and future technologies (robotics, advanced automation, etc.).

Therefore, as manufacturing becomes increasingly digitalised, supply chain models must also become increasingly digitalised by implementing the above technologies. And this will lead to end-to-end integration. Furthermore, with this evolution of the supply chain model, shorter lead times, increased flexibility through real-time optimisation, increased efficiency and increased transparency and personalisation of services will be observed. A digitalised supply chain model is one in which processes are connected through a sensor network and managed through a central data hub and analytics engine.

Adopting The Right Technologies Amidst Economic Uncertainty

Due to the ongoing trade war, there is a fear that demand and investments will shrink. Protectionist attitude and interest rates are also on the rise. Thus, manufacturers can make use of technologies and innovate their business models to improve their productivity, efficiency and competency in order to overcome the adversities ahead. With the right technologies, the industry may even disrupt and affect other sectors, causing a ripple effect that could accelerate the advancement of businesses embracing Industry 4.0 sooner rather than later.

 

David Chia

Automation Charter Chair, The Singapore Industrial Automation Association Managing Director, Beckhoff

In 2019, at the mass market stage, enterprise digitisation will penetrate deeper into the manufacturing floor. This will cause enterprises to look towards obtaining data from as many machines and sensors as possible, which is a trend that has continued on from past years.

Overcoming The Barriers To Digitalisation

In order to digitalise more effectively, companies have more to gain from standardisation than competition. Currently, Germany is leading the effort to create common industry wide standards and they have done quite well as the VDMA is leading the machine standardisation for Germany. Countries in the ASEAN region may need to follow on their footsteps. Next, governments across the region should also help in funding digitisation initiatives and this is especially important for SMEs.

Finally, re-training and upskilling the workforce is needed. We are facing shortages in data engineers, data scientists, data analysts in the region and re-training and upskilling is especially important as older manufacturing jobs disappear and newer ones are created in their place.

The Importance Of Data Collection, ML And AR Technologies

On top of sending data over standardised communication protocol, companies will increasingly look towards getting standardised information from each machine type. This so called “information modelling” and is relevant to a production line today as there is hardly a “homogenous” production line containing the same machine model from the same manufacturer.

Another focus for the metalworking and CNC world will be the use of AR technologies. While still a cutting edge technology today, this technology holds a lot of promise from speeding up operators to training, to advancing maintenance work. At the bleeding edge, we are seeing an increasing trend of ML implementation directly on a premise or machine. While this is on early stages, we feel that this would be the internal focus of many bleeding edge suppliers moving forward.

 

Alex Teo

Managing Director and Vice President, Southeast Asia, Siemens PLM Software

The outlook in Asia Pacific continues to be favourable in 2019. With a dynamic economy and an extremely fast-growing internet population, Southeast Asian markets are good options for companies looking to diversify and add to their operations in China. Especially as rising labour costs and increasingly volatile market conditions in China cause more firms to relocate their production in order to spread out risk and gain access to new markets.

The Growth Of Mass Customisation Focused Technologies

The shift towards a knowledge-intensive economy in Southeast Asia is a by-product of the global movement towards a more individualized and personalized consumption economy. Therefore, the region is expected to transit from the age of mass-production, to one of mass-customisation which is a trend that has been highlighted at the ASEAN Summit. Due to this, we are expecting manufacturers to adopt and implement technologies such as cloud-based product lifecycle management solutions, as well as Digital Twin technologies, in order to be able to produce meet the level of rigour and scale that is required for mass-customisation.

The Development Of Disruptive And New Technologies

Disruptive technologies such as robotics, computer numerical control (CNC) machines, additive manufacturing, artificial intelligence, scanning technology and smart devices will persist and will be ubiquitous across the product value chain. In the case of additive manufacturing, markets such as Singapore, China and South Korea have already identified it as a growth potential and are actively investing in the technology to create high-end jobs and services.

Additionally, Dyson has also announced plans for its first electric car, to be built in a new automotive manufacturing facility in Singapore that is set for completion in 2020. The selection of Singapore as a site for this facility – which has not seen automotive manufacturing since Ford closed its factory 40 years ago – is a surprise for many. This investment which is part of Dyson’s USD 3.3 billion global investment drive in new technology, is a game changer for the electronics and heavy machinery industries in the region.

 

Ian Roberts

Regional Executive Director, UBM

In 2019, the ASEAN region will remain as an attractive area for investment. The ongoing trade war between China and the USA is creating problems and opportunities within the ASEAN region as although foreign investment companies are starting to relocate their manufacturing plants away from China, countries within ASEAN particularly Vietnam and Indonesia, are benefiting from the relocation of manufacturing plants into their countries.

The Rise Of Indonesia And Vietnam 

Most of UBM’s trade shows have continued to grow, particularly in Vietnam where there are numerous opportunities in both HCM and Hanoi. Currently, the biggest problem for the organisation of events in Vietnam is the size of the venues in both HCM and Hanoi which restricts UBM’s expansion plans. However, this also reinforces Vietnam’s position as UBM’s strongest market since 2018.

In Indonesia, the economic growth in the short term will be modest due to the Rupiah depreciation as we all as the impact of the upcoming presidential elections in April.  This will affect overseas investment as investors take a “wait and see” approach. Thus, investments will be halted for at least the first half of the year. For this reason, Indonesia is expected to rely on domestic consumption and household spending to drive the economy. However in the long term, Indonesia remains a strategic and lucrative market for investors as it continues to offer strong economic fundamentals to spur the growth of the middle class and fuel consumer spending which is a key driver of growth.

Growth Of Smart Factories And Smart Manufacturing In Southeast Asia

Southeast Asia’s main selling point can no longer be its low wages if it is to remain competitive. Implementation of new technologies are needed to help close the productivity gap. This means factories will need to integrate technologies such as robotics to maximise productivity, minimise human failure and prevent work-related accidents. Aside from that, companies could integrate AI and data analytics to make automation processes more intelligent and to improve efficiency.

A report by McKinsey & Company has highlighted that Southeast Asia needs to embrace Industry 4.0 to unlock its potential in manufacturing. Through this report, it is stated that disruptive technologies associated with Industry 4.0 would have an impact on productivity on a scale that is similar to the introduction of the steam engine had during the first Industrial Revolution. Globally, if the digital technologies of Industry 4.0 were to be embraced and integrated efficiently, it is forecasted that it could contribute between USD 1.2 trillion and USD 3.7 trillion in business profits. Meanwhile in ASEAN, the impact of Industry 4.0 could see productivity gains of between USD 216 billion to USD 627 billion.

 

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Norbert Seo

Senior Vice President, Market Division Asia & Australia, Bystronic Pte Ltd

2018 was one of the most successful years for Bystronic due to numerous product launches in the gold, silver and bronze segments of the market as well as international business expansions.

In 2019, the economy is uncertain because of market turmoil and currency slumps but sheet metal continues to have a wide application in industries that are set for growth such as the automotive, semiconductor and electronic industries. Additionally, governments across Asia are continuously building and developing infrastructure and new industrial areas which create indirect opportunities for the sheet metal fabrication market.

The Growth Of Automation

The industry is currently in the age of automation. This is because automation allows for shorter lead times, greater accuracy, higher quality and competitive pricing. In the field of laser cutting, automation makes it possible to process not only large series but also small batch sizes, while maintaining the flexibility that users require to always respond to changing order situations.

Implementation Of Networked Production

With automation drastically changing the outlook of the sheet metal industry, Bystronic is systematically driving forward the vision of “World Class Manufacturing”. This is based on a comprehensive range of new products and services with which Bystronic is gearing its users’ process landscape towards networked production. It features innovative solutions that go far beyond the conventional idea of a machine tool. It’s about fusing the individual processes relating to laser cutting and bending into a network of intelligent components.

 

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Bystronic: World Class Manufacturing

Bystronic: World Class Manufacturing

With new solutions for sheet metal processing, Bystronic, a leading global provider of high-quality solutions for the sheet metal processing business, takes customers to the top of the competition at the EuroBLECH 2018 in Hanover, Germany.

At the most important sheet metal processing industry event, Bystronic presented comprehensive innovations for all aspects relating to cutting, bending, and automation. In the future, networked manufacturing processes, integrated automation, and digital service solutions will help customers to profoundly optimise the manufacturing of sheet metal products.

Bystronic is systematically refining the vision of “World Class Manufacturing”. This is based on a comprehensive range of new technologies and services with which Bystronic is gearing its users’ process landscape towards networked production. In this way, Bystronic accompanies customers step by step on their path towards the smart factory.

World Class Manufacturing goes far beyond the conventional idea of a machine tool. The focus lies on digitally networked production, which combines the individual processes related to laser cutting and bending to form a network of intelligent components. Users thus achieve a higher degree of flexibility and transparency in their production environment. Both are important prerequisites in order to manufacture products faster, more cost-effectively, and more intelligently than ever before.

Production Line: Fully Automated Laser Cutting

With the Production Line, Bystronic presented its highlight in terms of laser cutting automation. Within this fully automated manufacturing solution, sheet metal parts are pre-processed, cut, transported, and sorted according to orders. The heart of the Production Line is the ByStar Fiber laser cutting system. Powered by a 10kW aggregate, this is where the speed of the entire production process originates.

The ByTrans Cross and BySort loading and unloading automation is connected directly to the fibre laser. It handles the entire material flow between the laser and the integrated storage system. The storage system supplies all the raw metal sheets required for the cutting jobs: steel, stainless steel, aluminum, and non-ferrous metal sheets in thicknesses ranging from 0.8 to 25mm with a maximum overall capacity of 24 tonnes. It also returns finished cut parts and residual sheets to storage.

Bystronic presented a showcase at EuroBLECH to demonstrate a solution that will enable the Production Line to be expanded in the near future. ByFlex, an additional integrated system, drills holes and cuts threads into sheet metal parts prior to the laser cutting process. In addition, a labelling function marks the parts that are to be cut with a code. This allows all the information about the sheet metal parts that are being produced to be scanned in at the downstream processing stations.

Bending Cell: The Fully Automated Bending Centre

The Bending Cell automatically bends the cut sheet metal parts. For this, Bystronic expands the high-end Xpert Pro press brake with an agile robotics system. A 7-axis robot picks up the sheet metal parts that are to be bent, places them with high precision on the Xpert Pro for bending, and subsequently sorts them according to jobs. The Bending Cell can handle sheet metal parts up to 270kg.

With high precision, the robot also automatically sets up the press brake with the appropriate tools. To achieve this, Bystronic has integrated a tool magazine into the Bending Cell that keeps a range of required bending tools on standby. Thanks to a maximum press capacity of 320 tonnes, the bending automation solution can process a wide range of sheet metal products. The Bending Cell is ideally suited both for the efficient processing of high-volume repetitive jobs and for changing lists of jobs with small batch sizes.

Bystronic MES: Transparency From The Incoming Order To The Finished Part

The Bystronic MES is the navigation system for sheet metal processing. An intelligent software solution that helps users manufacture and ship sheet metal products with precisely defined costs and deadlines. The Bystronic MES determines the ideal path on which sheet metal products are guided through the processing stations for cutting and bending. This optimises throughput times and costs in the sheet metal production chain. And it helps users to perfectly attune all the process steps, machine systems, and workstations within their production environment.

Shop Floor Control System: The Digital Guidance System For Production Lines

In the future, how will users control and monitor production lines in which automated production cells and individual machine systems are networked? With the Shop Floor Control System, Bystronic showcased a newly developed software solution at EuroBLECH. Networked with sheet metal processing stations, the Shop Floor Control System assumes the centralised control function and helps users to always maintain an optimal production flow. The system also provides information about potential bottlenecks or downtimes within the production line. This enables scheduled production times and delivery deadlines to be adhered with a high degree of reliability.

ByStar Fiber: Laser Cutting With 12 Kilowatts

Bystronic projects promising prospects for fibre laser cutting: With 12kW, the high-end ByStar Fiber laser cutting system will soon feature a new performance level. This will boost the profitability and speed of the cutting process right up to sheet thicknesses as high as 30mm. This will provide customers with an almost unbeatable competitive edge in the competition for jobs. In order to optimally integrate the higher laser power into the cutting process, Bystronic has rigorously enhanced the design of the ByStar Fiber’s cutting head. Thus, users always achieve outstanding cutting results in a wide range of materials.

BySmart Fiber: The Fiber Laser For A Flying Start

The new generation of BySmart Fiber is already available now. Bystronic has fundamentally redesigned the entry-level solution for fibre laser cutting and expanded it with numerous features. The result is a versatile cutting system with up to 6kW of laser power and matching automation solutions. Thus, Bystronic is opening up the full potential of fibre laser technology to users in growth industries: high parts output, a broad spectrum of applications, and automation for optimised material handling.

Xpert Pro: Bending Technology For The Highest Demands

With the new Xpert Pro press brake, Bystronic is taking the successful Xpert product line a step further. The Xpert Pro supports demanding users with maximum flexibility and performance for the bending process. A variety of configurations are available for a wide spectrum of bending applications.

Features such as dynamic crowning and the patented pressure reference technology ensure consistently high bending quality on the Xpert Pro. On top of this, the Xpert Pro boasts intelligent assistance functions, such as the material curve generator and the LAMS angle measuring system. These enable users to achieve maximum precision from the very first bent part.

APMEN’s exclusive interview with Norbert Seo, Bystronic’s Senior VP Market Division Asia & Australia. By Ahmad Alshidiq.

What’s new from Bystronic in EuroBLECH 2018…

We have many new features on Industry 4.0. We have the full set of automation solutions with integrated software which allows you to combine automation with intelligent systems to monitor production schedules, machine status as well as to analyse the storage.

Bystronic’s main market in SEA…

Vietnam is our main market in Southeast Asia. We established our new demo centre in Ho Chi Minh last year. We call it the “Experience Center”, where we placed a laser machine and one bending machine. Malaysia market is looking interesting as well and we are looking at investing more in the country, in Thailand as well as Indonesia.

Industry outlook for 2019…

Business perspective is quite uncertain, however, we are looking at the demand of our customers and monitoring closely on where is necessary to expand our products and technologies.

What to expect from Bystronic in 2019…

We are launching a new series of BySmart Fibre from 2kW to 6kW which gives a lot of opportunities to the high-sensitive market. We are also attending seven exhibitions and are having five in-house shows in 2019.

 

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EuroBLECH 2018: Bystronic Displays “World Class Manufacturing” Innovations

EuroBLECH 2018: Bystronic Displays “World Class Manufacturing” Innovations

In time for EuroBLECH 2018, Bystronic is systematically driving forward the vision of “World Class Manufacturing”. This is based on a comprehensive range of new products and services with which Bystronic is gearing its users’ process landscape towards networked production. “We accompany our customers step by step on the path to the smart factory,” explained Bystronic CEO Alex Waser.

With “World Class Manufacturing”, Bystronic has described the matching supporting programme as one that features innovative solutions that go far beyond the conventional idea of a machine tool. It’s about fusing the individual processes relating to laser cutting and bending into a network of intelligent components, said Mr. Waser. Users can thus achieve a higher degree of flexibility and transparency in their production environment. Both are important prerequisites in order to manufacture products faster, more cost-effectively, and more intelligently than ever before.

In future, thanks to new software solutions, users will be able to create quotes more rapidly, plan their production processes in an efficient manner, and make the best possible use of their resources. Live monitoring systems represent an additional building block. They provide users with real-time information about the running processing steps from their production environment. All this will result in the optimisation of costs and processes. And this in turn, is the prerequisite for growth and sustainable competitive success.

With flexible system solutions, Bystronic is expanding the rules of the game in the field of sheet metal processing. Until now, there was always a trade-off between fast and versatile. In future, users will be able to produce small series or individual mass-produced products at conditions similar to a standardised high-volume series.  As commented by Mr. Waser, “With the new generation of our cutting and bending systems, users can adapt their processes much more easily and thus respond more quickly to their customers’ requirements.”

The integrated automation of production steps is another key success factor. To achieve this, Bystronic uses modular solutions for the material handling in the field of laser cutting. Automation systems that grow with the customers’ requirements and with increasing laser output. In the field of bending, the company is driving forward the development of flexible automation modules that enable fast transitions between automated and manual manufacturing.

Service remains another key issue for Bystronic. Within the networked production environment, network steps are interdependent. This makes process reliability and the preventive maintenance of all integrated systems more critical than ever before. New service solutions help users increase the efficiency and process quality of their production.

Learn more by visiting Bystronic at EuroBLECH 2018 from October 23 to 26, 2018 in Hanover, Germany. Hall 12, Booth B66.

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Step By Step To The Smart Factory

Step By Step To The Smart Factory

At the EuroBLECH 2018 exhibition, Bystronic is presenting the networked world of sheet metal processing. Under the motto “World Class Manufacturing”, customers and visitors experience live where integrated automation and new software solutions for laser cutting and bending are heading.

In time for EuroBLECH 2018, Bystronic is systematically driving forward the vision of “World Class Manufacturing”. This is based on a comprehensive range of new products and services with which Bystronic is gearing its users’ process landscape towards networked production. “We accompany our customers step by step on the path to the smart factory,” explained Bystronic CEO, Alex Waser.

With “World Class Manufacturing”, Bystronic describes the matching supporting programme. It features innovative solutions that go far beyond the conventional idea of a machine tool. It’s about fusing the individual processes relating to laser cutting and bending into a network of intelligent components, Alex Waser said. Users can thus achieve a higher degree of flexibility and transparency in their production environment. Both are important prerequisites in order to manufacture products faster, more cost-effectively, and more intelligently than ever before.

In future, thanks to new software solutions, users will be able to create quotes more rapidly, plan their production processes in an efficient manner, and make the best possible use of their resources. Live monitoring systems represent an additional building block. They provide users with real-time information about the running processing steps from their production environment. All this will result in the optimisation of costs and processes. And this in turn, is the prerequisite for growth and sustainable competitive success.

With flexible system solutions, Bystronic is expanding the rules of the game in the field of sheet metal processing. Until now, there was always a trade-off between fast and versatile. In future, users will be able to produce small series or individual mass-produced products at conditions similar to standardised high-volume series. “With the new generation of our cutting and bending systems, users can adapt their processes much more easily and thus respond more quickly to their customers’ requirements,” Alex Waser said.

The integrated automation of production steps is another key success factor. To achieve this, Bystronic uses modular solutions for the material handling in the field of laser cutting. Automation systems that grow with the customers’ requirements and with increasing laser output. In the field of bending, Bystronic is driving forward the development of flexible automation modules that enable fast transitions between automated and manual manufacturing.

Learn more by visiting Bystronic at EuroBLECH 2018 from October 23 to 26, 2018 in Hanover, Germany. Hall 12, Booth B66.

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Bystronic Acquires Majority Interest In Automation Specialist Antil S.p.A.

Bystronic Acquires Majority Interest In Automation Specialist Antil S.p.A.

Bern, Switzerland: In order to serve growing customer demands in the field of automation even more comprehensively in the future, Bystronic is acquiring 70 percent of the shares of Antil S.p.A. This majority shareholding in the Italian specialist for automated sheet metal processing will enable Bystronic to expand its existing range of technologies and services in the field of automation.

Nowadays, success in the field of sheet metal processing means: Manufacturing products quickly, economically, and in consistently high quality. At the same time the requirements with regard to simplifying complex processes and increasing overall efficiency are constantly growing.

This trend is changing markets worldwide and opening up new manufacturing opportunities. The automation of production processes represents a decisive step towards solving these requirements using technological solutions. By integrating flexible automation modules into the cutting and bending process chain, Bystronic already supports many users with a broad range of solutions.

With Antil, Bystronic can now offer complementary solutions for the loading and unloading of cutting systems, corresponding storage systems, and services.

Antil is an innovative technology company with headquarters in San Giuliano Milanese, Milan, Italy. Since 1989, the company has specialised in the development of automation solutions for the sheet metal processing industry. Its portfolio includes loading and unloading systems for laser cutting and punching machines, automated sheet metal storage systems, robot-assisted bending solutions, and customer services.

The company’s technologies and services are systematically oriented toward the requirements of its sheet metal processing customers. In 2017, it achieved a turnover of approximately 18 million euro.

With this majority interest, Antil is becoming an integral part of the Bystronic Group as a “Member of Bystronic”. Within this framework, the successful “Antil” brand will be maintained. Responsibility for its executive management will remain with the previous co-owner of the company Agostino Zanella. Its headquarters in San Giuliano Milanese and the employees there will also be retained under Bystronic’s majority shareholding.

“Antil and Bystronic complement each other ideally, not only technologically but also culturally. Innovations and clear focus on customer requirements are important components of both companies. This in turn benefits our customers,” Alex Waser, chief executive officer of Bystronic explained.

Waser continued: “In future, they will have access to a broad range of technologies for automated sheet metal processing. Together, Antil and Bystronic will support customer requirements with an outstanding sales and service organisation covering all aspects of automation.”

Bystronic Strong In Vietnam

Bystronic Strong in Vietnam

Ho Chi Minh City, Vietnam: Sheet metal processing companies in Southeast Asia are growing with Bystronic technology. In response, the company is expanding its local infrastructure in Vietnam for all aspects relating to consulting, sales, and customer services for latest technologies in the fields of laser cutting, bending, and automation.

The sheet metal processing industry in Southeast Asia is developing rapidly. Here too, an increasing number of users are relying on technologies such as the fibre laser, automation, and suitable bending solutions.

In order to provide its customers with even better support for their manufacturing processes, the company is strengthening its sales and service structures in the Southeast Asia market region. Recently, it enhanced its local presence here with the opening of an additional subsidiary in Vietnam.

Bystronic Vietnam held the official opening ceremony for the new subsidiary in Ho Chi Minh City in April 2018. In addition to sales and service areas, the new subsidiary is complemented with a demonstration centre, where it provides its customers with advice during live demonstrations in the fields of laser cutting, bending, and software.

Thus, the company now offers its customers in Vietnam two local points of contact for the consulting, sales, and service relating to the latest metal processing technologies at its business locations in Ho Chi Minh City and Hanoi.

Modular Automation Solutions Increases Efficiency For Sheet Metal Processing

Modular Automation Solutions Increases Efficiency For Sheet Metal Processing

We talked to Alex Waser, chief executive officer and president of Bystronic, and Norbert Seo, senior vice president market division Asia and Australia, for their insights into the rapidly evolving sheet metal processing sector.

As globalisation levels the playing field, the sheet metal processing sector is increasingly getting more competitive. Companies such as Bystronic are continually offering updated products and services that are more networked, automated and transparent.

For example, the company has partnered with software supplier Lantek to develop a manufacturing execution system that will allow users to digitally record and make optimal use of all the available resources on their shop floor.

We spoke to Alex Waser, chief executive officer and president of Bystronic, and Norbert Seo, senior vice president market division Asia and Australia, on other important advantages that manufacturers should seize in order to retain their competitive edge.

What are some of the most urgent trends that manufacturers worldwide should adopt? What impact will this have on users?

Alex Waser (AW): The integration of automation solutions and digital networking. I am thinking of modular material handling solutions for laser cutting. Compact systems that grow with the customers’ requirements and with increasing laser output. With regard to bending, I am thinking of flexible automation systems than enable fast transitions between automated and manual manufacturing. Thanks to the possibilities of digital networking, all these systems can be integrated into a transparent and maximally optimised manufacturing flow. They are controlled by high-performance software solutions that are simple to use.

Digital solutions and automation enable users to master fluctuating order situations using flexible systems. What is more, the manufacturing process will become more transparent. This will result in an optimisation of costs and processes. And this in turn, is the prerequisite for sustainable competitive success.

Norbert Seo (NS): The potential for the sheet metal processing in remains bright. For Asia, we believe the market trend will move with high-speed growth. Customers will require more high productive manufacturing machines. Thus, integrated production systems will require more know-how and skills from the customers. In return they will allow for higher productivity and profitability.

Sheet metal processing is seeing growth globally for Bystronic. What are your strategies for continued growth?

AW: The most important strategy of Bystronic is to support customers with technologies along the process chain of cutting and bending. In addition to high-quality products, we offer our customers comprehensive service solutions and the broad know-how of our technology experts.

This combination of leading technology, services, and know-how ensures our customers’ continued success and growth.

With the opening of the new Bystronic office in Singapore, what are your key priorities for the Southeast Asia region and the strategy towards achieving those opportunities?

NS: Singapore is a very important hub for our sales and service activities in the Southeast Asian region. The local sheet metal market in Singapore is very limited and slowing down, however, the strategic geographical location and the availability of highly qualified and skilled people make Singapore very important to us. Our key priority is to strengthen our local presence in the region to support our customers in the best way.

In 2017, Bystronic premiered in Japan at MF Tokyo. What industries are you supporting in the country?

NS: Japan is the second biggest sheet metal market in Asia after China. We want to be present there. We mainly support the job shop market but even the OEMs too. Our products are suitable to produce a very wide range of parts in different materials.

Manufacturers want to save costs while at the same time increase efficiency and transparency. How can you help them achieve their goals?

AW: With modular automation solutions that optimize the material flow in the laser cutting and bending process steps. These solutions are flexible and fit perfectly into our customers’ different manufacturing environments and they enable our customers to handle fluctuating order situations.

Also, our software solutions, such as BySoft 7, enable users to create offers more rapidly, plan their production processes in an efficient manner, and make the best possible use of their resources.

NS: We develop products and services to meet these needs. We even involve customers in product development. As a result, of all of our products including software and services are designed and built for high efficiency and productivity.

Please give us some final thoughts in terms of your company’s worldwide growth and expansion?

AW: The sheet metal processing industry in Asia and Southeast Asia is developing at a rapid pace. Increasingly, users are relying on technologies such as fiber lasers, automation, and suitable bending solutions. In order provide customers with even better support in these fields in the future, we are strengthening its sales and service structures in the Asian market regions. For example with newly designed offices in Singapore and the opening of brand new offices in Ho Chi Minh City.

In addition to the expansion of its sales and service structures, we are actively driving forward the development of new trends and technologies. To achieve this, we are investing globally in its development and manufacturing locations in Switzerland, Germany, and China, which are where the starting points for the innovations and high-quality process solutions lie, providing our customers with a competitive edge. Recently, we were awarded a certification for the high quality standards at the Chinese development and production location in Tianjin.

And last but not least, we are bringing our latest technology to Asian markets. Most recently, we introduced our high-end 10-kilowatt ByStar Fiber laser cutting system. 2018 will be an exciting year for our customers.

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