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The International Monetary Fund (IMF) estimates that the world economy will grow by 3.5 percent this year, with the impetus coming less from Europe and more from dynamic, newly industrialized countries. One example is the automotive industry. According to the association for the German automotive industry (VDA), China’s share of the market in passenger cars increased by 59% and that of Brazil by 18% during the first few months of 2013. The same market is also growing in India and Russia. For a long time, new production facilities have been planned and are under construction, providing great opportunities for the machine tool industry – as the example of EMAG proves. Specialists are developing turnkey manufacturing systems that are tailor-made to suit specific market conditions, with the new production facilities in particular gaining substantially from this increased market activity.
Whether in the automotive or energy supply industry, the development of industrial key sectors within the BRIC countries (Brazil, Russia, India, China) has a direct influence on the machine tool industry, as it is this branch that, in the end, must supply most of the necessary manufacturing solutions. There are numerous indicators for this fact. For instance, according to Germany Trade and Invest (GTAI), the Russian enclave of Kaliningrad will – over the next 3 years – will see an investment of 3 billion Euro in six assembly facilities and fifteen sub-supply companies for the national automotive industry, with more international sub-suppliers also establishing outlets in the market. Similar activities are reported from Brazil. According to Anfavea, the country’s automobile association, approximately 22 billion USD are to be invested in production between now and 2015. In India, economic growth is generally attracting “an abundance of investment projects in the country’s infrastructure, as well as in new industrial complexes,” states GTAI.
The German machine tool industry is prepared for such a dynamic development and the opportunities it provides can be seen in the textbook case of EMAG. Their specialists see themselves as “partners in solutions” for the metalworking industry. Such an approach is of great importance, especially in the emerging markets. “As it happens, we don’t just deliver a machine tool. We deliver closely pinpointed manufacturing solutions that are, in every respect, tailor-made to customer requirements”, explains Dieter Kollmar, Managing Director of EMAG Holding GmbH. “This applies, of course, to typical factors such as batch sizes, component variants or, more generally, the flexibility of the processes applied. At the same time, we determine locally the technologies, automation equipment, interfaces and control systems required.“ The advantages for the customer are obvious, especially where an existing production line is extended or where a greenfield manufacturing facility must be created in a new market place. Our manufacturing systems are always “from a single source.” Even complex processes with peripheral machines and equipment are presented as turnkey projects by EMAG, thus considerably reducing the efforts of local production planners.
VL 2: Highly effective, truly outstanding space saver
The VL 2 is a pick-up turning machine with which the EMAG engineers are fulfilling a combination of two extreme demands: highest possible output rates on the smallest possible footprint. “This is a truly all-important aspect,” confirms Dieter Kollmar. “Although the floor space requirement for this vertical turning machine is just about 5 square meters, it is a machine of substantial capability, including a fully comprehensive automation concept with conveyor belt, workpiece storage and pick-up spindle. In combination with vertical turning, this results in very fast machining processes. “In other words, short loading travel guarantees the lowest possible component cost. Compared to horizontal turning machines, productivity rates increase quite noticeably. And maintaining the VL 2 is simple. All service units are freely and quickly accessible. The user can set up the machine in one step. “That too is important, when productivity levels enter the equation. Operators without prior experience, working at a new and unfamiliar location, will be able to quickly familiarize themselves with the machine. All in all, this is an optimal solution for those who want to extend production with as little investment as possible,” notes Kollmar.
VT 2-4: For demanding shaft production
A similar approach is shown with the VT 2-4 Vertical Turning Machine, with which the EMAG specialists have created an equally fast manufacturing system for shaft production. Even demanding machining processes can be realized on it. When machining shafts up to 400 mm length and 63 mm diameter, component costs reduce considerably, with extremely short chip-to-chip times (as with the VL 2) being the reason. Workpiece grippers transport the workpieces into the machine and remove them again, once they have been machined. Depending on the workpiece, the changeover can be accomplished in just 6 seconds. And the actual turning process is fast, too. 4-axis machining allows the component to be machined from two sides simultaneously. Vertical alignment of the workpieces provides consistent process integrity, as the unrestricted chip flow prevents the formation of clusters in the machining area.
Central project management
“We are convinced that these EMAG solutions are optimally designed to cover not only the specific requirements of an emerging market, but also those of Europe and the USA,” as Dieter Kollmar his company’s philosophy. Everything is greatly simplified, starting with production planning, as there is no need for separate workpiece and finished component storage, with the added advantage of a reduced floor space requirement. At the same time, the EMAG Group engineers act as central project developers, having access to machines with optimal interfaces. This guarantees a fast run-in and makes the machines maintenance-friendly. “When it is a question of arriving quickly at a wholly integrated, highly effective manufacturing solution, this approach must – from our point of view – be the first choice,“ Kollmar concludes.
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