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Makino Asia’s Smart Factory Meets Sophisticated Precision Engineering Capabilities

Makino Asia’s Smart Factory Meets Sophisticated Precision Engineering Capabilities

Makino Asia, a leading provider of machine tools used across various industries including automotive, aerospace, medical, semiconductor and electronics, has recently showcased its smart factory at its regional headquarters in Singapore. The facility is designed to meet the growing demand for high-quality products and sophisticated precision engineering capabilities in Asia by adopting Industry 4.0 and the principles of Industrial Internet of Things (IIoT). The smart factory consists of an assembly factory and state-of-the-art machining factory, leveraging seamless automation and digital technologies to achieve high levels of productivity and connectivity between its robots, machines and other peripheral systems.

The combined facility is expected to increase machine production capacity to almost double its previous capacity. The new machining factory and existing assembly factory are connected by a link bridge for staff, and a canopy area for the transfer of materials between the two factories using automated guided forklifts (AGF).

The facility is also fitted with energy-saving and efficient solutions: green energy from installed solar panels within the compound helps to generate about 2,400 megawatt hours of energy annually. This is equivalent to taking 200 cars off the road, avoiding 1,000 tonnes of carbon dioxide equivalent emissions over the same period. In the machining factory, a chilled ceiling system is used to ensure maximum energy efficiency of its air-conditioning system while maintaining high quality, reliability and optimum performance of Makino Asia’s manufacturing operations.

Neo Eng Chong, CEO and President of Makino Asia said, “Makino strives for a ‘Quality First’ mindset across the organisation, from the manufacturing of our products to the development of our people and the business. We are extremely proud of our expanded smart facility in Singapore that will enable Makino Asia to better support our Customers in the region and Singapore’s vision to become a global Advanced Manufacturing hub.”

He added, “The automation and digitalisation of the entire facility serves as a way for us to achieve increased productivity, capacity or energy efficiency. More importantly, it embodies our vision to provide more than just machines for our Customers, by providing the most effective and efficient solutions that meet their needs. The establishment of the IoT Centre to provide real-time support is another milestone to enrich partnerships with our valued Customers.”

The monitoring and tracking of machine conditions in real-time enables Makino Asia to provide proactive and predictive services to Customers. This ensures optimum machine performance at all times so that Customers are able to consistently deliver high quality products.

Lim Swee Nian, Assistant Managing Director of the Singapore Economic Development Board said, “Global precision engineering manufacturing leaders are accelerating the adoption and deployment of Advanced Manufacturing technologies from Singapore, to better serve the evolving needs of their Customers. We are pleased that Makino will be deepening its 45-year presence in Singapore through the launch of its digital transformation journey. As Makino Asia focuses on building its Industry 4.0 capabilities to develop and scale new solutions, we are confident that it will create value-added roles and upskilling opportunities for Singapore to succeed in the digital manufacturing economy.”

Makino Asia embarked on its digital transformation journey in 2016 with a plan to invest around S$100 million over five years to expand and boost the capabilities of its facility in Singapore. The company also established two new departments focused on automation and digitalisation to catalyse digital transformation in the company.

Besides having “smart” machines and solutions, Makino is committed to upskilling all its employees to keep up with fast and ever-changing developments in the manufacturing landscape. Makino Asia’s new and current employees undergo a Workforce Transformation program focused on equipping them with automation skills, digital literacy skills and safety skillsets. The courses are mandatory for all employees to keep abreast of the digital technologies being used to manage automated equipment.

The manufacturing sector in Singapore remains a key pillar of Singapore’s economy. It accounts for around 21 percent of Singapore’s nominal Gross Domestic Product (GDP) and 14 percent of the total workforce. Rapid technological advancements and digitalisation are changing the face of manufacturing. Developments in Advanced Manufacturing presents opportunities for companies to leverage on new technologies to drive productivity and growth.

 

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Miniaturisation In Clamping Technology Thanks To Additive Manufacturing

Miniaturisation In Clamping Technology Thanks To Additive Manufacturing

Miniaturisation plays an important role in many industries, including machining manufacture. Therefore, clamping chucks also have to become smaller, more precise and more powerful. The requirements cannot be met with conventional manufacturing – MAPAL therefore relies on additive manufacturing by selective laser melting. Article by MAPAL.

Whether in electrical engineering, medical technology, the aerospace industry, the watch industry or robotics and mechanical engineering – many products are becoming ever smaller, yet smarter, more user-friendly and more powerful. The topic of space is therefore crucial. Because space is not only limited on the wrist, in trouser pockets, on board an aircraft or in the human body, but also in the production halls of companies.

This requirement gives rise to the demand for productivity in the smallest possible space, which transfers the cycle of miniaturisation to the entire value-added level. Machine and tool technology in this small sector requires more and more functions having to be fulfilled in the smallest space, also in the area of clamping technology.

Perfect Radial Run-Out And Optimum Balancing Value

The radial run-out accuracy of the clamping chucks for a chipping thickness in the range of a few thousandths of a millimetre must be almost zero. This is the only way to achieve good surfaces at maximum spindle speeds with a long tool life. In addition, it must be ensured that any contamination due to microparticles is excluded. Another important topic for machining in the miniature sector is the supply of coolant lubricant. Too much medium means complex downstream part cleaning, too little or no cooling leads to a loss in quality and productivity.

If handling should also be simple, conventional manufacturing reaches its limits. The smaller the tool and clamping chuck, the easier handling must be. Because with each reduction, the handling of external peripheral devices becomes more complicated and more difficult. With shrink or collet technology, it also takes considerably longer for the tools to be ready for use. In the case of multi-part attachments, the individual deviations of the components also add up to a considerable error chain.

Additive Manufacturing By Selective Laser Melting

At MAPAL additive manufacturing by selective laser melting is used in all product areas. And this is the case in all situations where additively manufactured products can offer clear added value for the customer. Thanks to this innovative manufacturing process, MAPAL has succeeded in manufacturing clamping chucks in miniature format with HSK-E25 connection, for example for direct clamping of tools with a diameter of 3 mm. And these miniature clamping chucks meet all of the above requirements.

The Smallest Clamping Chucks With The Best Properties

In order to guarantee radial run-out accuracy, the clamping technology specialists have integrated innovative clamping chamber systems into the new clamping chucks, which fit snugly against the tool shank. They are equipped with dirt grooves to displace microscopic dirt. The required balancing value is ensured thanks to internal balancing geometries including support structures, which also optimise weight and strength. Overall, with the chucks in a small format, there can be achieved a more homogeneous and spindle-friendly acceleration and braking of the entire tool system consisting of clamping chuck and tool.

Thanks to additive manufacturing, MAPAL has succeeded in equipping the clamping chucks for the miniature sector with decentralised coolant outlets. Using parameters such as coolant pressure, setting dimension and spindle speed, these outlets are designed in such a way that they convey the coolant lubricant directly to the cutting point. In the best case, a dosed loss lubrication, which makes subsequent cleaning of the parts superfluous, is achieved.

Very Easy Handling Without Peripheral Devices

The new clamping chucks from MAPAL in a small format enable simple and quick clamping of the tool. Neither training courses nor high retooling costs or expensive peripheral devices are required for implementation. Because the hydraulic chucks are operated using a simple screw.

New Possibilities – Not Only For Tool Clamping

The new small hydraulic chucks also open up new possibilities for workpiece clamping. For example, for clamping hip joint balls. Here the external hydraulic clamping technology is used. Specially shaped chip flutes inside the chuck and a special external geometry ensure that the balls are clamped very precisely and gently at the same time. In medical technology in particular, topics such as reproducible precision are of enormous importance. And this is ensured during machining thanks to the new chucks.

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[TMTS 2018] Interview With Mr. Ryan Liu From CNC-Takang

[TMTS 2018] Interview With Mr. Ryan Liu From CNC-Takang

Asia Pacific Metalworking Equipment News is pleased to conduct an interview with Mr. Ryan Liu from CNC-Takang regarding his views on the current and future market outlook for Taiwan’s metalworking industry.

Mr. Ryan Liu from CNC-Takang

1.What has been the business focus of CNC-Takang in 2018?

Originally, the company’s main markets are in Russia, India and Western Europe such as Germany. However, the company is now shifting its focus to the US and the Southeast Asian market due predominantly to currency challenges in other markets. The company also has an office in the US as strong service standards are required in order to meet market demands as well as the country’s strict regulatory requirements. Similarly, in order to meet the quality standards in our markets in the US and Europe, our products have been certified to be able to meet DIN standards.

2. What would be the company’s business focus in 2019?

As the US economy is growing, the US market will be an area of focus in 2019. This is also because the Taiwanese market is currently experiencing limitations due to the policies by the Chinese government and local manufacturers will require more support from the Taiwanese government as well as the establishment of more trade agreements if they were to invest their growth in the local market. In the meantime, other markets that are of interest to the company are Vietnam and Thailand as both countries are experiencing growth in their economies.

3. What do you think will be the trends in Taiwan’s metalworking industry in 2019?

Due to the ongoing trade war, the Taiwanese manufacturing industry will experience a downturn at least till the first quarter of 2019. This is also because the larger Taiwanese manufacturers have factories in China and at least 30 percent of their exports are being produced from their factories in China.

4. What are your views on the Taiwan International Machine Tool Show (TMTS) 2018?

The show has improved every year and the location of the show in Taichung is optimal as 90 percent of the local machine building industry and its associated supporting industries are located here.

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Tornos Launches Customer Service Centre In Shanghai

Tornos Launches Customer Service Centre In Shanghai

Tornos Shanghai has officially opened its new customer centre in Shanghai’s Pudong Pilot Free-Trade Zone. This is in recognition of China’s status as the largest industrial market globally. The new centre will accommodate the company’s full range of machines and brings Swiss operational excellence to the doorsteps of customers in Greater China.

The inauguration of the new customer centre in Shanghai also underscores the power of three legendary entities—Tornos, Switzerland and Shanghai—Turning Together toward the future. Present for many years in China, Tornos inaugurated its first subsidiary in Shanghai in 2004. For both Tornos and Shanghai, the past 14 years have been an amazing journey and the Tornos’ customer centre in Shanghai will strengthen the company’s regional presence and fortify its standing as the partner of choice in machine tools.

Tornos, China And Switzerland: A History Of Collaboration

This year, Tornos also celebrates the fifth anniversary of its Tornos Xi’an plant. And with internationalisation as a top priority, Tornos is strengthening its flexibility and growing through innovation to enhance its operational excellence every day. With the opening of its customer centre in Shanghai, Tornos ramps up its offering of unique solutions for targeted market segments – an approach that has met success in Greater China.

And there is more to come: Tornos plans on increasing its visibility in this market region, and the customer centre in Shanghai will play a big part in this strategy. In fact, this centre is a clear sign of Tornos’ commitment to this market and to its customers.

The new centre is equipped with the latest technologies and will provide quality support to Chinese customers. With a surface area of more than 1,500 square meters, it includes a training center, showroom, metrology room and a stock of spare parts.

In terms of applications, the centre will make full use of Tornos’ know-how across a wide range of industrial segments—including automotive, micromechanics, electronics and medical & dental—with the goal providing turnkey machining solutions while being close to the market. The purpose of this technology center is to maximise support for Tornos’ customers in the production of parts in small or large quantities in China. This support ranges machine support and operator training to the supply of spare parts, technical assistance and programming advice, as well as expertise on the best choice of tools and clamping devices.

Close To Customers, Wherever They Are In The World

Thanks to its new center in Shanghai, Tornos will be faster, more efficient, more responsive to its local customers as this enables the company’s technicians to expedite machine set ups and partnerships with customers. An open house for the customer centre in Shanghai will occur on November 8.

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Amba: “All-In-One” Bolt Production Machine

Amba: “All-In-One” Bolt Production Machine

Amba’s “All-in-one” machine allows for the production of upset bolt blanks of 60 to 200 mm in length at a rate of up to 400 bolts per minute or 24,000 pieces per hour. In contrast, bolts in lengths between 160 and 180 mm are typically produced at a rate of 60 pieces per minute.

This increase in throughput is done by first upsetting one end of the rod, then rotating the rod and upsetting the opposite end—in an integrated secondary upsetting station the machine. The thus produced bolt blanks have a head at both ends. At the end of the process, they will be cut in half.

Getting Up To Speed

Getting Up To Speed

“Fibernomics” (as coined by Bystronic), describes an all-encompassing economic principle which seeks to give the competitive advantage in today’s sheet metal fabrication environment. It begins with the company’s fibre laser cutting system. Contributed by Oliver Hergt, editor corporate communications, Bystronic.

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