DMG Automation boosts the productivity and quality of it customers by developing flexible production cells and complete production lines.

Rising demands on quality, fiercely competitive markets and an increasing shortage of skilled workers – any machining company wishing to remain competitive is being confronted with ever greater challenges. Automation of machine tools is regarded as the ideal response to this trend, because it opens up completely new manufacturing possibilities. DMG Automation GmbH has concentrated on this field since 2007 and as an absolute specialist now offers its customers integral solutions that if requested also incorporate the entire manufacturing process including the accompanying material flow concept.

“Our task consists of increasing the productivity and quality of machining production with the aid of customized automation solutions,” is how Uwe Kling, CEO of DMG Automation GmbH, sees the core business of the GILDEMEISTER daughter. The situation on the market also confirms the high demand: “In particular in the years following the economic crisis we have registered considerably greater growth in the automation sector than in the demand for machine tools themselves.” Before that the growth trends were the same. However, the range of products and services at DMG Automation has also developed since then. Whereas at the beginning we were concerned primarily with workpiece handling, today the focus is not only on this machine-integrated automation but on three additional segments as well: standard automation for workpiece and pallet handling for one to two machines, flexible production cells for the fully automated linking of several process sequences and production lines, that can be implemented as a complete solution in large series production. The latter variant also includes among other things the material flow for the respective production. Uwe Kling explains: “We support customers throughout the entire process development to ensure the finished system is optimized ideally in line with the respective products”.

DMG / MORI SEIKI has more than 66,000 installed machines alone on the German market and most of these have not yet been automated. Uwe Kling is faced with the challenge of convincing these machine owners as well as new customers of the advantages of an automation solution. But this does not necessarily entail automating a machine no matter what the cost: “There are always workpieces and machines where an economic automation solution is just not feasible and in such cases we advise against automation,” says Uwe Kling. “Our aim is to build up long-term partnerships with customers.” That is why cooperation for DMG Automation starts with a non-binding assessment of the machining situation. This is an important step for the CEO: “There are many things that can be automated in principle, but automation is only expedient if by its implementation we increase productivity and / or machining quality.”

Additional shifts without additional manpower costs

Uwe Kling now gets down to the crux of the matter with regard to automation: “Productivity is the main concern of most users, because it plays a major role in the competitiveness of a machining company.” So the aim is to produce more per unit of time – generally with higher quality – and in so doing to reduce production costs. Automation meets both these requirements, because it promotes low-manpower production in which staff shortages have virtually no impact on production. It enables the introduction of additional shifts outside of normal working hours as well as costs that are clear and calculable. “This also puts the user in a position to respond to the shortage of skilled workers, because competent workers can be deployed specifically for more demanding tasks instead for the handing the workpieces,” adds Uwe Kling.  So in the last instance one worker can take care of several machines or job orders at the same time. Uwe Kling also promises a fast return on investment with proportionate utilization of the machine:  “In the ideal scenario costs are paid back within less than a year.”

DMG Automation has a holistic approach with its portfolio, so that users can profit from automation to the full. This means that workpiece and pallet handling constitutes only a small part of its offer. “Today we focus primarily on complete manufacturing processes and their optimization”, explains Uwe Kling. The work therefore includes not just workpiece handling but the linking of machining centres and, if possible, integrating secondary work parallel to primary machining time. “Integrating deburring, brushing, cleaning or measuring operations is no problem at all." Every automation solution is based on modular components that are adapted individually to bring them in line with the requirements of the customer. With around 900 workpiece and pallet handling systems already installed, the company certainly has ample experience.

Automation competence and customer-orientated service

The experience gained in the countless number of projects realised by DMG Automation is clear proof that the respective systems have attained their set targets.    25 % increases in productivity and improved workpiece quality are the norm. Uwe Kling gives the reasons for this: “Many faults arising from human error are eliminated thanks to automatic handling. So we achieve higher workpiece accuracy through reliable loading and unloading processes.” Another reason is flexible production: “Each automation solution can include individual workpiece magazines which allow perfectly organised processing of the job orders.” User-friendliness is clearly paramount here. The modular design of the automation cells also encompasses other areas: controls from Siemens, Fanuc, Kuka or Motomann are available as well as various gripper systems and conveyor installations and the option of robots or gantries for handling.

Where user-comfort is concerned, DMG Automation relies mainly on machine tools from DMG / MORI SEIKI. Work ergonomics are also given top priority in addition to simple operation as Uwe Kling stresses: “An automated machine should offer the same perfect accessibility as the machine itself.” This applies most especially to the setup and loading stations, although the work area must also be easy to access if necessary. In addition the CEO also sees service as being of central importance:  “After all we ensure that the automation operates smoothly and reliably with our service offer.” For DMG Automation service starts with the installation of the system and training of the employees in the operation of the new system. “It only takes a few days to integrate the automation solution into the production,” says Uwe Kling.

Ultimately, DMG Automation does not only gear its offer towards customers from DMG / MORI SEIKI. In principle every machine can be automated. Uwe Kling proves that this has long been the case by taking a look as the order distribution: “About a third of our customers also commission us to automate machines from other manufacturers.”