Machinery & Manufacturing Issue 4 | July/Aug 2022

ISSUE 4 | JULY/AUG 2022

Optical inspection takes a technological

leap forward WATCH VIDEO

Page 30

Talking Tech: Industry 4.0 in your hands with Mazak iCONNECT EuroBLECH 2022

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EXCLUSIVE INTERVIEW Lloyds Banking Group : An upbeat assessment

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Machinery & Manufacturing

Contents 7 Thought : Super deduction How much can you really save?

Our Team Editorial Director - Laura Crawford laura@machineryandmanufacturing.com Contributing Editor - Steed Webzell steed@machineryandmanufacturing.com Circulation Enquiries circulation@machineryandmanufacturing.com Advertising Enquiries hello@machineryandmanufacturing.com Editorial Submissions editorial@machineryandmanufacturing.com

Catch up

What’s been happening?

Let’s talk : Manufacturing An upbeat investment assessment Aerospace Robotics solutions from EROWA Industry 4.0 Smarter use of the shopfloor Handling Solutions Raising efficiency Talking Tech We discuss Mazak iCONNECT Front Cover Showcase New TAGLENS TM from Mitutoyo Tooling Technology Expansion thanks to Ceratizit Sheetmetal Prima Power is up to the challenge

Welcome... Welcome to issue four of the fantastic Machinery & Manufacturing magazine, crafted by dedicated Engineering Media professionals especially for the machine tool intensive manufacturing community. With a passion to support the metalworking & manufacturing sector in it’s post pandemic recovery, we invite you to enjoy an immersive reader experience to be enjoyed on or alongside your desktop, phone or tablet. I’m a hybrid! How do you use me? Click or scan the play buttons for instant video Click or scan the download buttons for instant brochure downloads, discreetly appearing on your device in a separate file ready for you to simply hit save.

5-Axis Machining Endurance from Heller

Published in an eco-aware format by Engineering Media Ltd.

Automotive Inspection accuracy with DigiMic

Company Number : 13634129 VAT Registration 397 8226 41 Our registered office address is :

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20-22 Wenlock Road, London, N1 7GU Maidstone Office : +44 (0)1622 296112 In our mission towards carbon neutral, we publish and replant in partnership with:

Cleaning & Degreasing Gearing up for expansion Celebrating Success Growth at GM CNC keeps coming

Inspection Coordinating Quality

Automation Breaking performance records

Spotlights 3D Printing & Cutting Fluid

Show Preview EuroBLECH 2022

Honing Innovation from Sunnen

Software Solutions Keeping pace with hyperMILL

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CNC Machining Rock on with ETG

Grinding Mazak return to STUDER Coolants & Lubricants Cost savings stay fluid

Machinery & Manufacturing

A new survey by BPI Auctions, which specialises in the sale of pre-owned assets, claimed that only one in eight (12%) of those questioned said they knew of the Government’s super-deduction capital allowance on plant and machinery investments. This rather measly percentage is somewhat troubling, as it means a great deal of you are likely missing out on a potentially large tax break. The Government introduced the incentive in April 2021 to stimulate investments in machinery and improve economic growth, which had inevitably deteriorated during the Covid-19 pandemic. It runs until 31 March 2023, providing you with an unmissable opportunity to save money. In short, you can cut your tax bill by up to 25p for every £1 you invest! Unfortunately, much of the UK’s productivity gap is attributable to our historically low levels of business investment compared with our international peers. Weak business investment has played a significant role in the slowdown of productivity growth since 2008. Making capital allowances more generous works to stimulate investment. As a result, measures such as the super-deduction capital allowance can promote economic growth, but only if word spreads! To set out the potential savings available, imagine you invest £100,000 in a new CNC machine tool and decide to claim the super deduction. Spending £100,000 on qualifying investments will mean you can deduct £130,000 (130% of the initial investment) when calculating your taxable profits. Deducting £130,000 from taxable profits will save you up to 19% of that, or £24,700 on your corporation tax bill. As the ancient proverb says: better than a poke in the eye! So why not cash in and make that all-important investment you’ve had on ice for the past couple of years? The clock is counting down! Who doesn’t love a deal - Get spending! Laura Crawford Editorial Director Super deduction: How much can you really save?

Is your CMM looking tired? Are you using outdated technology in your measurement and inspection department? Swap out your current CMM for a significant trade-in discount of up to 30% Bridge the gap in your current quality operations with a new CMM. By trading in your old Hexagon or non-Hexagon machine. Learn how

Catch up

Rolls-Royce enters hydrogen production market Rolls-Royce is entering the hydrogen production market as it takes another step forward in the drive to improve sustainability of the aviation industry. The company is acquiring a 54 per cent majority stake in electrolysis stack specialist Hoeller Electrolyzer, whose innovative technology will form the basis of a new range of mtu electrolyser products. Hydrogen is an increasingly attractive power source to fuel the green energy transition and demand for ‘green’ hydrogen – which creates no CO2 – is expected to rise significantly. www.rolls-royce.com

Protolabs, which supports thousands of companies in the UK and Europe every year, has launched a new injection moulding Consultative Design Service that will tap into the critical thinking and problem solving of its 200-strong team of engineers. Already known for its automated design for manufacturing analysis via its digital quoting platform, the new offer has the potential to help clients across numerous industries optimise performance of its components, reduce manufacturing costs Consultative Design Service for Injection Moulding

Smaller turn-mill centre for one-hit production of complex parts

The NTX series of B-axis turning and milling centres built by DMG MORI has been expanded by a new model at the smaller capacity end of the range, which now comprises five machines. The compact NTX 500 is able to turn components up to 558 mm long and 120 mm in diameter, or up to 40 mm diameter from bar, using its two Y-axis tool carriers and twin opposed 8,000 rpm turnMASTER spindles. The size of the machine coupled with its

power and rigidity make it especially well suited to the production of implants and other medical parts from challenging materials. Automation solutions are available for the turning centre, including integrated bar feeding from the right hand side and an in-machine travelling robot (IMTR) that allows automatic workpiece unloading from the main and counter spindles. www.dmgmori.com

and shorten lead times. www.protolabs.co.uk

Bowers Welcomes Sales Manager

GTMA announces new CEO This year marks the GTMA’s 80th Anniversary and provides an opportunity for a new and exciting chapter as the current chief executive Officer, Julia Moore, hands over the reins to her successor, Dr Alan Arthur. “I have been CEO of the GTMA for in January 2020 as chief technical officer and brings with him a working knowledge of trade associations and a strong background in engineering which will be a great asset to the GTMA,” stated Moore.

Bowers Group is delighted to announce that Jordan Gould has been promoted to the position of Central East Sales Manager. Jordan joined Bowers Group in 2020 as Mobile Metrology Centre Demonstration Manager and enjoyed enormous success delivering detailed product demonstrations across the UK for the full range of metrology products, as well as driving sales and acquiring new business. www.bowersgroup.co.uk

almost 25 years and I am looking forward to handing over to Alan, who joined the GTMA

www.gtma.co.uk

Machinery & Manufacturing

New PCD Line for High-Speed Milling Catch up

Catch up

Jaguar Land Rover appoints Barbara Bergmeier

Barbara is appointed to the newly created role of Executive Director and will lead Jaguar Land Rover’s new Industrial Operations organisation, which incorporates the

With the global launch of the new ADDFORCE brand from Tungaloy that now introduces the very latest cutting tool innovations, the cutting tool manufacturer has introduced its new TungRec DX110 Series of PCD insert grades for unrivalled performance when machining aluminium alloy components. The Tungaloy TungRec milling range has long been an exceptional performer with its innovative tool bodies and insert geometries, but now, this line is set to take aluminium machining to a new level with the new DX110 PCD insert grade.

Kleos Space opens UK facility at Space Park Leicester Kleos plans for the new UK facility to provide access to a tech community, and facilities for research, development, and manufacturing. Space Park Leicester is a project led by The University of Leicester in partnership with local authorities that space capabilities and companies dealing with satellite design and engineering, through to downstream data and its applications. AST SpaceMobile opened a headquarters at the complex last year. “The Space Park offers a fantastic work environment for us, and with its plans for the future and potential opportunities for collaboration, it is a great fit for our strategy to grow to meet the demands of our customers,” said Kleos’ Global Chief Innovation Officer Miles Ashcroft. www.kleos.space

Reading is a vital skill that is stimulated throughout a child’s time at school, but at Mount Street Academy in Lincoln, where all children are under the age of seven, they are also encouraged to see the joy in reading and the Academy has relaunched its Reading Rewards program that gives added incentive to read more, this is being aided by the donation of a vending machine from speed, this reconfigured organisation and Jaguar Land Rover’s robust, sustainable end-to-end supply chain as part of a fully connected industrial strategy. In turn, this will deliver greater efficiency and resilience of the company’s industrial operations across a connected global landscape. Barbara joins Jaguar Land Rover from Airbus Defence and Space, where she was Executive Vice President & Head of Operations. ww.jaguarlandrover.com responsibilities currently split across manufacturing, purchasing and supply chain teams. This change consolidates accountability for the complete ecosystem of how the company produces vehicles, in one place. A key priority will be to transform, at

www.tungaloy.com

ANCA Tool of the Year 2022

In an industry moving at lightning speed, ANCA Tool of the Year celebrates the deep experience and creativity of the craftspeople who create the next generation of cutting tools. To find the Tool of the Year customers can submit their favourite tool with the winners

The second category is for virtual tools as the “Most innovative tool design”. Entrants are encouraged to be creative and use ANCA tool design software to push ideas to their limits. The winner of #MadeonANCA

receives $10,000 AUD worth of ANCA innovations for parts, accessories or software that fit

being judged and announced live at IMTS. There will be two competition categories to recognise both the functionality and creativity of cutting tool manufacturers. The main prize goes to #MadeonANCA tools and entrants will be judged on the form and performance of their cutting tool.

your grinding needs or a trip to ANCA’s headquarters in Melbourne, Australia. This amazing prize comes with access as an ANCA VIP to exclusive opportunities with our ANCA experts. www.machines.anca.com/ Tool-Of-The-Year

Ceratizit encourages reading uptake

Ceratizit UK & Ireland. www.ceratizit.com

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Catch up

3D Printing Tech for ‘TAP’ BCN3D Technologies’ constant strive for

obtain material properties and applications otherwise unreachable with other resin-based technologies, and by revealing its commitment to delivering VLM systems to 20 of the companies currently enlisted in its Technology Adoption Program (TAP) during Spring 2023. “The overwhelming initial reception for our most recent innovation has surpassed our expectations and set the tone for the onset of the distribution of our first VLM commercial systems. We’ve been able to hone in on what really matters to each individual company by gathering real, tangible information from experienced engineers. ”- Xavier M. Faneca, CEO of BCN3D.

innovation had led the 3D printing experts to its never-before-seen 3D printing technology using high viscosity resins. Developed over the course of the last 3 years, the patented Viscous Lithography Manufacturing (VLM)™ provoked mass interest worldwide. BCN3D has responded to the demand by partnering with Arkema and Henkel to

www.bcn3d.com

largest such group of researchers in the world, and sits at the heart of the university’s commitment to establishing Nottingham and the East Midlands as a hub for the translation of net zero technologies from research bench to real world solutions. The building is also home to the Government-funded Driving the Electric Revolution Industrialisation Centre - Midlands, which is developing innovative technology and manufacturing processes for advanced electrical machines and drives to support the UK’s net zero ambitions, and houses the 20MW UK Electrification of Aerospace Propulsion Facility, which offers industry testing at a scale unrivalled by any other research centre in the world. The facility is funded by UK Research Partnership Investment Fund, Wolfson Foundation, DER, D2N2 and industry partners.

A £40 million research facility that will drive forward advances in powerful, clean electrification technology and pave the way towards a new generation of low-carbon, sustainable electric vehicles, power and propulsion is to be unveiled by the University of Nottingham. The state-of-the-art Power Electronics and Machines Centre (PEMC) on the university’s Jubilee Campus was opened by the university’s Vice Chancellor, Professor Shearer West, in June. The PEMC offers purpose-built laboratories for the Power Electronics, Machines and Control research group, the New facility to drive a revolution in green electric transport

Machinery & Manufacturing 12

Let’s talk: Manufacturing

investment assessment An upbeat

Dave Atkinson, UK head of manufacturing, SME and Mid Corporates at Lloyds Banking Group, talks with contributing editor Steed Webzell about the transition to net zero, post-pandemic recovery and super-deduction tax relief, all of which are driving investment Climate change poses a risk to every aspect of the planet, threatening to wreak havoc to the natural environment, to communities, livelihoods and the economy. For manufacturers, reducing carbon emissions and achieving net zero is therefore essential. Although the journey to net zero poses several challenges, this transition has the potential to drive investment, innovation, job creation and earnings. Our UK Manufacturing: Now to Net Zero report published last year found 6% of manufacturers have already achieved net zero, while 47% have set out targets to follow suit, which is a credible ambition when you think about the challenges surrounding expertise, resources and budget,” states Dave Atkinson, UK head of manufacturing at Lloyds Banking Group. There are many drivers at work here, including one that may prove a surprise. “During recruitment processes, younger- generation candidates are asking potential

employers about their environmental goals, as they only want to work for companies with a credible sustainability story that’s focused on delivering net zero,” says Mr Atkinson. “If manufacturers chose not to travel the road to sustainability, not only will they miss out on cost savings and growth opportunities, but also on new talent.” Scope 1, 2 and 3 set out ways of categorising different types of carbon emissions. Here, Mr Atkinson suggests Scope 3 is currently “looming large” for SME manufacturers. “OEMs will soon have to start publicly reporting their Scope 3 emissions, which means they’ll be heavily reliant on supply chain SMEs being net zero, or at least having a roadmap to net zero,” he says. “This is where growth opportunities are emerging: those in the supply chain who can demonstrate net-zero activities are becoming more attractive to OEMs.” Sure enough, achieving net zero is not easy, particularly with so many other challenges for manufacturers to combat, such as inflation, the energy crisis, supply chain shortages, staffing levels and the ongoing pandemic. However, there is a clear need for manufacturing plants to do something. But where do they start? In November 2021 Lloyds Bank published ‘From Now to Net Zero: A Practical Guide for SMEs’. The publication sets out a number of defined steps, including: getting started; short-term wins and employee engagement;

“those in the supply chain who can demonstrate net- zero activities are becoming more attractive to OEMs.”

measure, mobilise and monitor (setting targets and objectives); and navigating the road ahead (tactical investments). “It almost doesn’t matter where you start, as long as you start,” says Mr Atkinson. “It could as simple as changing your energy supplier to a provider of renewable energy, looking at the type of lighting you use, or setting up more segregated waste streams for recycling. Simple things, but important nonetheless. At Lloyds we have a Green Buildings Tool, an interactive digital portal that can help you identify energy- efficient investments within your buildings.” A self-audit is among the suggestions for those looking to embark on the journey to net zero. Lloyds recommends engaging the workforce in this activity as they will have ideas on how to improve. “We offer a Clean Growth Sustainability Audit Guide to help SME manufacturers set

out the net-zero process: where am I at the moment, where could I get to, and how can I start this journey?” explains Mr Atkinson. “As a point of note, all of our relationship managers have been through a robust and comprehensive training course with the Cambridge Institute of Sustainability Leadership, so they can have better quality conversations with manufacturers. Ultimately, we have our Clean Growth Financing Initiative, where SME manufacturers can access discounted lending for green purposes.” Among the success stories is cutting tool specialist Guhring Ltd, which through financial support from Lloyds has invested in five new electric vehicles to bolster its commercial fleet, alongside two hybrid models. The move has the potential to reduce Guhring Ltd’s carbon footprint by more than 25%. According to Mr Atkinson, those companies that are investing and making the transition

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Machinery & Manufacturing 14

Let’s talk: Manufacturing

“We all know that investment in technology and skills drives productivity, and a productive economy leads to higher standards of living”

The Government’s super-deduction tax relief is among the drivers of this investment, which according to Mr Atkinson represents a fantastic opportunity for manufacturers. “We all know that investment in technology and skills drives productivity, and a productive economy leads to higher standards of living,” he says. “I’m sure many have been taking advantage of the super-deduction scheme, which doesn’t end until March 2023, so there’s still time.” Aside from being the headline sponsor of the MACH exhibition for the past 12 years, Lloyds is clearly not short of manufacturing credentials. Managers at the bank undertake training at WMG (Warwick Manufacturing Group), not to become engineers, but to understand manufacturers better. Lloyds has also invested around £10 million into the Manufacturing Technology Centre (MTC) in Coventry. This investment will support the training and upskilling of around 3500 graduates, engineers and apprentices by the end of 2024. In addition, the bank works with the MTC to offer a manufacturing support service that helps de-risk any potential investments. “We were founded by two industrialists in Birmingham in 1765, so manufacturing is endemic in our history,” concludes Mr Atkinson. “Sure enough, there are plenty of challenges for manufacturers at present, but in my 34 years of supporting these companies at Lloyds, I’ve learnt about their resilience, agility and determination. When one door closes, manufacturers somehow find the key to open another. I’m really excited about what this sector can achieve in the years ahead.” n

to net zero are seeing opportunities in both UK and overseas markets. Any new business opportunities will of course be warmly welcome in the post-pandemic recovery. The challenges of the pandemic left a number of manufacturers using lockdown periods to reflect on their processes and shop-floor layouts. Many also began identifying future investments. For instance, the need to address skills shortages has seen growing investment in intelligent automation and robotics. Says Mr Atkinson: “We did some work with the MTA (Manufacturing Technologies Association) around four years ago looking at what we call the ‘multiplier effect’ of

UK manufacturing businesses. While UK manufacturers employ around 2.6 million people, we discovered they create a further 2.4 million jobs indirectly, plus an additional 2 million roles created through the spending of those direct and indirect employees. So in terms of the sector’s importance, we estimate it’s actually responsible for around 23% of GDP rather than the official figure of 10%. We shouldn’t lose sight of the importance of this sector, and this sector shouldn’t lose sight of the importance of investment. Here at Lloyds we’ve seen good levels of sustained investment across the industry, whether using balance sheet liquidity or funding that we can provide.”

www.lloydsbankinggroup.com

Watch the video

Machinery & Manufacturing 16

Retrofit Robot Packages Can they really help deliver growth for the Aerospace sector?

The 2021 edition of PwC’s ‘Global Aerospace and Defense: Annual Industry Performance and Outlook’ shares key performance metrics of the global commercial aerospace and defence industry drawn from the 100 largest companies by revenue. With civil aircraft production set to ramp up and new challenges in the defence arena, the supply chain will need to keep pace

has stated plans to ramp up production of that model to 31 per month in 2022. Airbus also plans to increase production of A320s to 45 per month by the end of the year. The Biden administration looks to increase military spending, while Europe’s elevated levels of terror threat and continuing tensions with Russia means defence budgets are expected to grow. The UK, Germany and France all confirmed their intention to reinforce their defence capabilities. However, this may not result in a large number of new programmes. Instead, the requirement will be to rapidly develop new intelligence and cyber capabilities.

“By using automated loading, a machining centre typically runs much more economically”

According to the report Boeing has more than 400 737 MAX aircraft in inventory to deliver and

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Machinery & Manufacturing 18

Aerospace: Manufacturing Solutions

a Robodoor for machines without an automatic door and the dimensions of the door are optimally adapted to suit the machine; and machine preparation of the interfaces between the machine and the handling robot which are configured to suit the application. Automation training is also taken care of. After installation and setting-up of the Retrofit Robot Package employees will receive comprehensive training in the correct use of the new automation system to ensure the business gains the expected benefits. Ongoing support will also be provided when required, such as when new staff are expected to support the automation. An optional addition to the package is the EROWA JobManager JMS 4.0 ProductionLine, the universal production process control system for many machining operations. This practical online process control system provides automatic management of machines and loading robots. Within the overall concept of Industry 4.0, EROWA’s production process control system occupies an important position. It maps a large part of the functionalities that fall under the heading of ‘smart factory’. This provides machine shops using chip- cutting production with significant advantages: “Making the most of the available production time the business already has will keep any company competitive and ensure promised delivery schedules are achieved”

Managing Director of REM Systems, UK and Eire agents for the Swiss automation specialist, Ian Holbeche, explains: “The long-term forecast for commercial aerospace appears very positive. Just consider, for example, that 82% of the global population has yet to set foot in an aircraft, and, with the global middle class projected to grow from 25% to 60% by 2030, there is an enormous untapped segment of new customers. This adds up to a significant increase in the delivery demands placed on the supply chain – our customers.” He continues: “Retrofitting an EROWA Robots to an existing lathe, machining centre, mill-turn or even a combination of these machines in a cell will allow any machine shop to operate effectively around-the-clock. And, you do not even have to pay for holidays, sickness, overtime, employee contributions so the benefits quickly add up.” For just a small investment an EROWA Robot Easy or Robot Compact 80 can achieve a very quick payback. Efficient productivity, flexibility and process reliability are more important than ever in these difficult times. Making the most of the available production time the business already has will keep any company competitive and ensure promised delivery schedules are achieved. The EROWA Robot Easy 250 offers a small footprint, from only 3 m² (1.7 by 1.7 m). The Robot Compact 80 fits within a 2 m² footprint and can lift up to 80 kg. Both Robots are suitable for side and frontloading installations making them flexible enough to fit into any available shopfloor space. Everything required to ensure the automation system runs perfectly is included in the Retrofit Package. It comprises of an Air Dock System that allows 5-axis machines without a compressed air supply for the chuck on the machine table to be reliably automated;

it provides a clear view at all times of every workpiece being processed, their exact locations and how far into the process each is in real-time. It links up all the data and controls the entire production process. Its software connects machines with the widest variety of manufacturing technologies without any problems. Ian Holbeche states: “By using automated loading, a machining centre typically runs much more economically. The hourly output increase by a factor of three or more. So, hourly machine rates can be reduced thereby improving competitiveness.” Putting forward a simplified calculation that highlights the benefits of the Retrofit Robot Package, he says: “If we compare a CNC machine tool investment of £300,000 against the additional investment of £85,000 required for the retrofit package. Without automation on a single shift with an operator the machine has 1,500 available hours. The overhead cost will be around £80 per hour with an earning or charge out rate of £100 per hour the payback period is around 6 years, a 9% ROI.

“With the robotic automation and the same single shift operator, the machine’s available hours increase to 5,800 per year. This reduces the overhead cost to around £35 per hour and allows the business to reduce the charge out rate to £70 per hour, thereby increasing the competitiveness of the business. This results in a payback period of less than 2 years which equates to an ROI of over 80%.” Of course, every application is different but exact calculations for any machine shops ROI can be provided by REM Systems’ experienced staff. As Ian Holbeche concludes: “Given the current extended waiting times for new machine tools, that could lead to capacity shortfalls that could be addressed by the EROWA Retrofit Robot Package. Robotic automation also supports the current environmentally conscious principles of making the most of what you have already got – effectively making more with less.” n

www.remsystems.co.uk

Watch the video

The EROWA Robot Easy 250 available in the UK via REM Systems

Machinery & Manufacturing 20

It’s time to make smarter use of shop floor intelligence... Industry 4.0

Securing Quality Together

UK manufacturing SMEs are being urged to link their critical success factors to the shop floor for gathering all-important real time data relating to productivity, quality and safety. With so few companies using shop floor intelligence there are significant gains to be made – because the process involves all functions in a business – plus it’s a concept that teams are able to get their heads around quite easily says LMAC Consulting, who are specialists in Industry 4.0 adoption and the world-leading Smart Industry Readiness Index (SIRI). Shop floor intelligence involves collecting real time, accurate and critical data – like progress tracking of jobs, quality of products, productivity of machines and everything in between – so that it can be processed and analysed to optimise performance and efficiencies.

LMAC MD Alastair Crawford, who was one of the very first certified SIRI assessor for the UK, explains: “The majority of companies we have taken through SIRI end up with this as one of their main priorities. In today’s dynamic, fast changing environment, the ability for people or systems to have the right information at the right time is critical to success. People resonate with this dimension and are often frustrated by the lack of timely data preventing them from doing their job. “They can see how it will impact their role, which is exactly the kind of insight we need people to get to grips with if they are to embark on the journey to Industry 4.0 maturity.” When building a client’s smarter Industry 4.0 roadmap, LMAC encourages them to engage in a simple yet revealing critical data exercise. This involves mapping the process and the data set they should be evaluating, to ensure they have the best possible visibility of those parameters to make informed decisions that will improve their performance. The information gathered helps evaluate current shopfloor KPI maturity and also understanding of any gaps that exist and where they need to be closed. Crawford adds: “It’s not just about the sexy tech which can be involved in Industry 4.0 adoption that turns heads. Rather, the data that new tech produces rules the roost – and not only the collection of the right data, but the transfer of that data to where we can do something useful, tangible and game changing with it.”

www.lmacuk.co.uk

www.accretech.eu

Machinery & Manufacturing 22

Handling Solutions

Hérige Group subsidiary Atlantem, a French producer of aluminium, PVC, wood and hybrid windows as well as entrance doors, garage doors, gates and roller shutters, took the opportunity during the construction of its new, 20 million euro factory at Saint-Sauveur-des-Landes in Brittany to optimise stocking and flow of materials. To automate logistics in the manufacture of its products, the company chose German storage and sawing equipment manufacturer KASTO to supply an automated UNICOMPACT honeycomb warehouse. Long stock is reliably supplied to around 15 workstations and storage of remnants is also managed. The manufacturer employs 850 people at nine sites in France. In the 2019 fiscal year, sales amounted to 140 million euros, making the company the leading supplier of products in this sector in the French market. They are delivered exclusively to construction firms and the building trade throughout France via four distribution channels. No products are exported. Atlantem has grown steadily since it was established in 1995, partly through the acquisition of several companies. Jérémy Jouvrot, manager of the Continuous Improvement department explained, “We face clear challenges to remain successful, as customers demand high quality at competitive prices. Our strength is to offer standard windows, doors and other products in all materials.” continued >>

with Automated Storage Raising Efficiency

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Handling Solutions

“KASTO has fully met our high expectations. The storage and handling system was installed and commissioned on time and on budget. It has significantly reduced our employees’ workload.”

The move into new headquarters in Noyal- Pontivy last year was an important milestone in the company’s history. The new administration building was designed in collaboration with the staff and serves as a showcase for the expertise of the entire Hérige Group. Construction of the new plant in Saint-Sauveur-des-Landes on an 18,000 square metre site had already begun a year earlier for the production of multi-material windows and doors. Mr Jouvrot emphasised, “We have created a highly networked factory. The Industry 4.0 plant is intended as a showpiece for our industry and will serve as a pilot project for the optimisation of our other manufacturing centres.” His goal was to optimise processes within the new building and so he was looking for an efficient system for material storage and supply. A centralised system was needed for storing all of the company’s profile and feeding it automatically to sawing machines. Additionally, a dedicated station was required to allow orders to be prepared by picking from multiple cassettes. It also needed to be capable of sorting and storing profile returning from a coating unit. Atlantem did not take the search for a suitable partner for this project lightly. A specification sheet containing all important parameters for the new storage system was created and before a supplier was selected, about ten users already equipped with various solutions available on the market were visited.

Mr Jouvrot explained, “We selected KASTO as it offered efficient and highly automated options for storing profile. Furthermore, it has a subsidiary in France (as it does in the UK and elsewhere) and therefore a field service team was able to respond quickly if required.” KASTO recommended its UNICOMPACT honeycomb-type, material-to-operator storage and retrieval system, which starts at around 400 stock locations. It can be either a self-supporting silo structure with roof and wall cladding or a stand-alone unit in existing buildings. The high storage density ensures efficient use of space. Fast cassette cycles in fully automatic operation enable short retrieval times for efficiently supplying the machines processing the material. The storage system continuously maintains an inventory, allowing orders to be picked economically. The system is of modular design, so modifications and capacity increases can be implemented quickly. The installation in Saint-Sauveur-des-Landes contains 1,504 storage locations and is 52 metres long, 22 metres wide and 16 metres high. Each cassette measuring 6,600 x 760 x 770 mm accommodates a maximum load of one tonne and enables storage of profile directly into the cassette or within customer racks. The energy-efficient operating gantry crane (OGC), which handles two cassettes simultaneously, reaches speeds of up to 160 m/min in longitudinal travel, while the lifting

beam moves at up to 50 m/min. Modern drive technology in combination with KASTO’s system software optimises its performance. Jerk-free starting and braking prevents profiles from shifting when the cassettes are transported. The system is controlled by KASTOlogic warehouse management software, which manages inventory data as well as machining orders. Due to the modern graphical user interface, system operation is effortless by menu navigation. Error displays and diagnostics are shown in plain text, so the user is able to assess the operating status immediately. A mobile, ergonomic operating panel with a 7-inch touchscreen allows the OGC to be moved manually during maintenance. The new storage solution has impressed the management team at Atlantem. Mr Jouvrot said, “KASTO has fully met our high expectations.

The storage and handling system was installed and commissioned on time and on budget. It has significantly reduced our employees’ workload. “We prepare orders from several cassettes and the system runs smoothly and fully automatically. The control software, which is linked to our ERP system, was delivered with modifications perfectly customised to our method of working. In addition, handling operations for feeding our machining stations have been simplified.” In summary, he said that Atlantem will use KASTO again for future storage solutions at other sites. Clearly the supplier knows the user’s requirements but more specifically, as its ERP system now has an interface to the KASTO software, implementation of future projects will be simplified. n www.kasto.com

Machinery & Manufacturing 27

Machinery & Manufacturing 26

Talking Tech

Let’s talk: Digital Connectivity

Mazak iCONNECT

Various service levels So, what can iCONNECT provide? Well, three service levels are available, not dissimilar to Amazon Prime membership in terms of structure: a free web service for registered users that provides access to a number of useful customer service features; a subscription service (called M2M) that offers an additional set of higher-level services; and in future the option to make one-off payments for access to even more options. Users of the free service can look at machine manuals and download their service information and spare part ordering, for example. They can also access FAQs and download free trials of production support software. Further features at this level include the ability to view maintenance videos, engage in online chats with Mazak representatives and access an e-learning catalogue containing training materials. “You can see whether the machine is currently running; the 24-hour utilisation log of that machine; the program in use; the machine’s operating parameters; the tools in cut; alarm status; and much more,” explains Mr Cocks. “Imagine you are a small business owner who runs shifts. With iCONNECT you can easily monitor the utilisation of machines from home. For example, what state are the override buttons; is everything running at 100%; is an operator in front of the machine? You can also perform a CNC back-up, uploading your control parameters and programs to the cloud.” The M2M subscription model connects customers’ machines securely to a cloud server via Cisco IoT hardware. Another option is remote support, where Mazak can dial into the machine’s control and talk the customer through a new application or support a maintenance task. There is also a spindle analysis function and much more. Moving forward, Mazak

will continue growing the advanced service functions available on iCONNECT. For practical purposes “With all iCONNECT services, including the free ones, it’s about the practical application of the technology, rather than buzzwords that don’t really mean anything to most within the machining community,” says Mr Cocks. “When developing iCONNECT we had to think about how the services would benefit our customers, how they would make machines more efficient, and how users could make more money from their investment.” The highly secure iCONNECT is currently in the roll-out phase and will go live towards the end of the summer, when all Mazak customers will be able to register for access. “We’ve taken a careful and methodical approach to furnishing iCONNECT with functions that customers actually need – at the lowest possible cost supported with industrial- grade hardware – so they can see a clear return on their investment in this technology,” concludes Mr Cocks. “We’re already seeing an eagerness from customers to on-board quickly, so we anticipate high uptake.” n “The goal was to deliver a practical, useful, cost- effective online customer service tool”

Put industry 4.0 in your hands

In discussion with contributing editor Steed Webzell, Greg Cocks, senior manager - European sales engineering at Mazak Europe, reveals all about the company’s new iCONNECT online service With a growing need for manufacturers to centralise the management of their various machine tool information sets, Mazak is introducing iCONNECT, a new online platform that delivers highly practical customer service functions through digital connectivity. Accessible to registered Mazak customers, iCONNECT provides a host of user benefits, including remote machine diagnostics, monitoring and maintenance, as well as professional training resources.

The development of iCONNECT was no small task. In the first instance, as one of the biggest machine tool builders in the world, Mazak has a sizeable customer base. Providing these customers with quick and easy access to their Mazak information, while adhering to relevant regulations and ensuring complete system security, was a challenge, but one the company was determined to get right. The goal was to deliver a practical, useful, cost-effective online customer service tool. “Our approach was very much based on ‘voice of the customer’, where we went to great efforts to find out what our users actually wanted from iCONNECT,” states Greg Cocks, senior manager - European sales engineering at Mazak Europe.

www.mazakeu.co.uk

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Machinery & Manufacturing 29

Front Cover Showcase

for speed Vision

The patented Mitutoyo TAGLENS™ technology resolves a vast array of challenges that the industry has struggled with until now. When inspecting electronic components such as PCBs and other precision parts, inspection times can be excessive and multiple cumbersome measurement devices are often required. With its large depth of focus even in high-magnification situations, the TAGLENS™ eradicates the need for focal adjustment to improve processing speed and inspection efficiency. Furthermore, the innovative new device cuts inspection costs by eliminating the need for a mechanical auto-focus unit – a feature that makes the TAGLENS™ an efficient and compact solution when compared to traditional technologies. In addition, the new Mitutoyo TAGLENS™ is perfect for high-speed imaging. By capturing multiple deep images at a single time, the system is ideal for destructive testing applications where detailed images of moving parts, such as crash tests. Crash testing captures the aftermath of a collision and with the TAGLENS™, scattered debris or chips can be captured with credit to the large focal depth of the system. Another application area of increasing importance is automation and robotics. When mounting an inspection device on a robotic arm, it is time-consuming to observe and measure a workpiece from various angles and distances. Once again, the TAGLENS™ resolves an ‘age-old’ industry challenge as the impressive focus characteristics eliminate the need for adjustment. This speeds up the inspection process by measuring the part regardless of the angle and orientation of the robot – increasing speed, overall efficiency, measurement accuracy and conformance. The TAGLENS™ suite of products includes the TAGLENS-T1 ultra-high-speed varifocal

lens with a resonance frequency of 70KHz and an effective aperture of 11mm diameter. The unique ability to change focus in 70kHz enables productivity and cost improvements across a wide range

Optical inspection has taken a technological leap forward with the arrival of the new TAGLENS™ series of products from Mitutoyo. For any manufacturer involved in optical measurement, there are several known challenges when measuring three-dimensional targets – Mitutoyo now eradicates these issues with its patented TAGLENS™. Ideal for demanding inspection applications such as non- contact ultra-high-speed inspection systems, the TAGLENS™ series reduces the need for mechanical focusing modules. Optical inspection of 3D targets with conventional lenses often raises issues with variable distances, inclination, movement and reflections – luckily the Mitutoyo TAGLENS™

is anything but conventional. The combination of these problems means that some surfaces will be out of focus in every image. Mitutoyo’s patented new TAGLENS™ has an unparalleled ultra-deep focus that captures in-focus images instantaneously to accelerate productivity and efficiency with optical measurement processes. The exciting new TAGLENS™ is the first ultra-high-speed variable focusing lens capable of operating in tough industrial environments. It incorporates an ultra-fast varifocal lens that guarantees to keep your target component in focus when inspecting – delivering unsurpassed observation and measurement efficiency. The extremely wide focus range of the TAGLENS™ allows the real-time probing of multiple heights or depths without vertical (Z-axis) motion. Furthermore, the incredible new system is not sensitive to orientation around a component or surface. This makes the TAGLENS™ the perfect solution for inspecting at a variety of angles and inclinations around a sample. This enables industry to now inspect components by moving the TAGLENS™ system around the part and not having to orientate the part, which can be an issue in production line situations. To deliver results you can trust, the TAGLENS™ is available with a Pulsed Light Source (PLS) that enables a focused image in any vertical Z-axis position to be captured without a mechanical drive system within the observation range – this is a credit to the extended focal depth of the TAGLENS™.

of quality assurance processes. Furthermore, this 0.6kg lens can be mounted at any angle and has a guaranteed operational temperature range of 15 to 30 degrees C, increasing the flexibility of the system. To take the scope of this innovation further, the TAGLENS-T1 can be integrated with the Mitutoyo VMU-T1 video microscope unit. By incorporating the objective lens and the camera, users can configure a varifocal microscope with the option of an objective lens of 1X, 2X, 5X, 7.5X, 10X, 20X and 50X. An additional option is the PLS light source. This LED pulse illuminator combines with the TAGLENS-T1 to achieve focused image acquisition and 2D image synthesis at the desired position. The VMU-T1 is the first commercial system to incorporate the TAG technology. The unique combination embodied in the VMU-T1 results in a powerful inspection tool which, when using Mitutoyo’s M Plan Apo Series of objectives, generates world-leading imaging depth-of-field capabilities that are up to 20 times greater than other similar microscopy inspection systems. n www.mitutoyo.co.uk/taglens

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Machinery & Manufacturing 30

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