Following the promulgation of the Special Economic Zone Act in 2014 (SEZ Act of 2014) which then saw proclamation for commencement on the 9th of February 2016, the Minister of Finance, Nhlanhla Nene approved the six SEZs preferential tax treatment status in terms of section 12R of the Income Tax Act (“s12R”).
“The Coega SEZ being amongst the six SEZs with an approved status provides a long awaited relief for the qualifying companies operating within the SEZ,” says, Dr Ayanda Vilakazi, CDC Unit Head Brand, Marketing and Communication.
The incentives, will also serve as good news for some of Coega’s largest foreign investors, including First Automotive Works (FAW) valued at R600 million and BAIC SA with an investment value of R11 billion, which recently launched their vehicle assembly manufacturing plant at the Coega SEZ.
“The announcement by the minister goes a long way in wetting investor appetite and adds to the attractiveness of various SEZ’s. As the CDC, the incentives continue to expand the capacity of Coega SEZ to invest in more innovative measures in enabling growth,” concludes Vilakazi.
The Steel and Engineering Industries Federation of Southern Africa (SEIFSA) welcomes a second consecutive increase in output of the metals and engineering (M&E) cluster in two months, SEIFSA Economist Marique Kruger said.
SEIFSA Economist Marique Kruger.
Speaking after the release of the latest preliminary seasonally-adjusted data, Kruger said the increase in production in June, which follows a similar upward trend in May, is welcome, despite lingering concerns about the possibility of a lower-than-expected contribution of the broader manufacturing sector to gross domestic product (GDP) in the second quarter of the year.
“The data, released by Statistics South Africa, captures an increase in output in the subindustry, in line with the broader manufacturing sector, which also increased by 0,7% in June 2018 when compared with June 2017. After adjusting for the sectoral weights, the data indicated that production in M&E sub-sectors increased by 4,1% in June 2018 on a yearon- year basis and by 2,4% on a month-on-month basis,” Kruger said.
She said notwithstanding the general increase in gross output, concerns remain that the contribution of the cluster and the broader manufacturing to GDP is still negligible because of proportionately higher intermediate input prices and production costs, including fuel and energy costs.
Kruger said input prices can be very volatile because of factors affecting supply, including the unpredictable exchange rate. Moreover, the demand for intermediate input tends to be more price inelastic, with overall demand remaining about the same whether input prices increase or decrease. She said this made it easier for suppliers to pass on frequent price increases to producers or buyers since their demand remained more or less the same, thereby accounting for the volatility in input prices.
She said the rapid depreciation of the randdollar exchange rate also increased the price of imported intermediary inputs and adversely affected the M&E cluster’s contribution to GDP.
Nevertheless, Kruger said the improvement in gross output augurs well for local producers, amidst escalating trade war rhetoric as the US and China continue to exchange threats of further tariff increases.
“The expectation is for the positive output trend to continue in July 2018 in line with an improving domestic manufacturing index, which rose to 51,5 in July from 47,9 in June, signaling an expansion in local production activities. The improvement in the local manufacturing purchasing managers’ index to an expansionary territory aligns with the global manufacturing index, which continues to perform well at 52,7, remaining above the neutral 50-point mark for a sixth consecutive month,” she said. A positive local output growth trajectory – which is consistent with global trends – bodes well for the M&E cluster, said Kruger.
Can South Africa’s manufacturing sector create a million jobs by 2027 amidst a stagnant economy and the much-anticipated fourth industrial revolution, which is likely to result in further mechanization within the sector and a possible influx of imported goods from China as it seeks new markets following the current trade war with the US?
This question will take centre stage at the 2018 Southern African Metals and Engineering Indaba, which will take place at the IDC Conference Centre in Sandton on 20-21 September. Deliberating on this question and suggesting ways to make a million jobs target achievable will be Manufacturing Circle CEO Philippa Rodseth, SEIFSA Chief Economist Michael Ade, Highveld Structural Mill CEO Johan Burger and Department of Economic Development Deputy Director-General Zeph Nhleko.
Last year, the Manufacturing Circle launched its Map to A Million New Jobs in a Decade plan, with the organization’s chairman André de Ruyter saying at the time: “If manufacturing can expand to 30% of GDP, between 800 000 and 1.1 million direct jobs can be created, with 5 to 8 times that number in indirect jobs,” he added. “Our Map to a Million puts forward detailed proposals to deliver a million jobs in manufacturing in the next decade.”
In the past two decades, the manufacturing sector has shed half a million jobs. At just under 13%, it contributes less than half to GDP than is appropriate for South Africa’s stage of development.
“The Map to a million is an initiative we strongly support as a Federation representing companies operating in the metals and engineering cluster, which forms part of the broader manufacturing sector. We believe that, similar to mining and agriculture sectors, manufacturing is one of the backbones of South Africa’s economy. We are of the view that it is of paramount importance that South Africa reindustrializes and restores its manufacturing sector to its former glory, in the interest of economic growth and employment creation.
“It is, therefore, against this backdrop that we felt it was important to use the platform provided by the Indaba to critically review the initiative and find ways of ensuring that it succeeds,” SEIFSA Chief Executive Officer Kaizer Nyatsumba said.
Responding to the recent news of investment into a $10-billion metallurgical complex development in Limpopo’s Special Economic Zone (SEZ) by Chinese investors, the Southern Africa Stainless Steel Development Association (Sassda) has announced it welcomes any and all beneficiation of South Africa’s raw materials, particularly chromite.
However, it was quick to state that it was rather in the downstream manufacturing and conversion of primary stainless steel products to finished products where the potential for significant job growth and value lies in kickstarting the country’s economic growth. Sassda Director John Tarboton says, “we salute government initiatives to grow the stainless steel industry in South Africa, however, it needs to be part of an integrated global value chain if it seeks to boost the economy in any meaningful way. Our industry is calling for beneficiation which will directly impact both jobs and the bottom line. In reality, there is no room for additional supply into the local market.”
Sassda, which heads up the stainless steel industry in South Africa focusses on promoting the sustainable growth and development of the industry, with their main emphasis on stainless steel conversion within the South African economy.
Currently, the stainless steel industry employs 114 000 people and is worth around R40‑billion to the South African economy from the primary production of stainless steel through to finished products, handling 500 000 tons per annum (tpa) in steel sheets, plates and coils. South Africa imports a further 40 000 tpa of which 150 000 tpa is consumed and 390 000 tpa exported.
It is in the conversion of primary products to finished products where most jobs and value are created, with between three and five employees needed per tonne of primary product converted per year, depending on the industry. Peak consumption of stainless steel primary product in South Africa was in 2014, when 200 000 tonnes were locally consumed.
South Africa and Zimbabwe own 85% of the world’s chromite reserves (the key ingredient for stainless steel production) and 70% of the world’s chromium is used in the production of stainless steel. South Africa also has about 80% of the world’s manganese reserves which is used in some stainless steel grades. According to Tarboton, it has long been the vision that South Africa maximise its beneficiation of chromite to stainless steel to move down the value chain and create local employment, together with the call for an export tax on chromite ore to support chromium beneficiation.
Process technologies for ferrochromium, nickel pig iron (NPI) and stainless steel are developing at a rapid pace around the use of backward integration into the mines to reduce energy consumption and create 4-in‑1 stainless steel mills. These technologies are reducing stainless steel production costs dramatically, while competitor products such as aluminium are seeing production costs rising above inflation (including in China) due to the rise in electricity costs. It is expected that this trend of stainless steel becoming cheaper will support the current global stainless steel growth rates of around 6% in the foreseeable future with the possibility of stainless steel production migrating to the mines in support of these new technologies in backward integration.
Together with Zimbabwe’s recently signed Memorandum of Understanding for a feasibility study for a stainless steel plant; South Africa’s proposed Musina Makhada SEZ plant is set to produce stainless steel to be further processed in China; however concerns remain regarding logistics and transport costs for its export.
According to Tarboton, “we have a globally competitive stainless steel producer in South Africa and they export about three quarters of their production. Any new stainless steel producer would have to be export driven. Currently, beneficiation would make the biggest economic impact to our industry, along with that of employment.”
True legend and icon in South Africa’s Machine Tool Industry Frank Thompson has died at the age of 80, following a dreadful sickness.
Born in Belfast, Northern Ireland, Frank made the decision way back in 1962 to immigrate to South Africa, which also started something of a flood of Thompsons to South Africa, many of whom also found their niche in the machine tool industry.
On arriving in South Africa, Frank joined Broderick Engineering as a Machine Tool Fitter before moving to Benoni to take up employment in machine tool maintenance and tool making.
After a few years at Parkin Machine Tools, during which time Frank rose to both a Director and Shareholder of the company, he decided it was time the family set something up and joined his brother Fred in forming F. Thompson Machinery in 1971. Over the following years the brothers developed the company as one of the leaders in the used machine tool industry.
By 1983, his two younger brothers, Philip and John, had become an integral part of F. Thompson Machinery and Frank took the decision to sell his portion to the brothers and form his own company, Harp Machine Tools.
As his other interests, among cycling, golf and horse racing, were taking up much of his time, Frank started off Harp on a very small scale. However, machinery was still much in his blood, and he found himself becoming more and more involved in the business. He once said, “it was not until my son Seamus joined me in the machine tool business that Harp really took off.”
After spending six months training in England with reputable companies Axe and Status and Wickman Exector, Seamus returned to South Africa and together with Frank they set about establishing Harp Machine Tools as one of the largest stockists of used machine tools in the country.
They both agreed to buy and sell only quality machines and not run of the mill stuff so prevalent in the used machine tool industry of that time. The company stocked some of the larger type machines, such as 80mm to 180mm horizontal boring mills, Webster and Bennets 36″ to 120″ vertical boring machines, large capacity guillotines ranging from 10mm to 20mm and 3m to 8m lathes. However, they also stocked smaller capacity machines, making them a truly one-stop-shop for the engineering industry.
While initially only dealing in used machinery, Harp eventually ventured into importing new machinery. The company became sole agents for the Kingrich range of machinery manufactured in Taiwan and soon also introduced the Harp SMTCL and Accurl brand name to the South African Market. Harp Machine Tools also represents manufacturers, such as Vertex, Easson, Sahinler, Toptech and the Baoji Machine Tool Group of China.
Frank’s name is synonymous with the local used and new machine tool industry. He was a founder member of UMTMA and has served the body as Chairman, Secretary and Committee Member since its inception and until it closed down in 2016.
A simple act on May 4th, 1776 of machining a cylinder for a steam engine was the beginning of precision and quality manufacturing and the catalyst that introduced the 1st industrial revolution, or should we say, Industry 1.0.
At the heart of our industry today is the fourth industrial revolution, Industry 4.0 and we are pleased that there is now a national strategy to embrace it.
The Intsimbi Future Production Technologies Initiative (IFPTI) has been developed with the principals that address the 4th Industrial Revolution and encompasses initiatives that will align us with advanced, developed economies.
It is the manufacturers’ function to produce good quality, low cost, affordable products. The future of manufacturing lies in our ability to adapt to the fast changing world and, we need association on the following very important pillars namely, Interaction, Specialised Knowledge, Compliance and Representivity. Now, we have to add a 5th, Inclusivity.
Paul Savides, Chairman MTMA.
This is why, during last year’s Machine Tools Africa exhibition, hosted by the MTMA, the modern era of artificial intelligence, machine learning and robotics played a significant role. Task reducing technologies (AI) are at the forefront in our industry and what was seen as disruptive technology, is now an industry norm with Industry 4.0 being the current trend of automation and data exchange between manufacturing stages and technologies that significantly improve productivity.
At the Machine Tool Merchants Association our members are up to the challenge of facing the increasing demands on the resources of companies. We believe that machine tools are the backbone of all our industries. Now, there are also new technologies that enhance the ability of a machine tool that was designed primarily to do subtractive machining, namely additive manufacturing.
While the manufacturing sector, if funded correctly, could become South Africa’s powerhouse we, at the MTMA, are ready to accept the challenge backed by our suppliers’ vast knowledge and experience in manufacturing, this would undoubtedly boost and develop South Africa’s economic position worldwide.
As we reach the fourth quarter of 2018, it seems we are already significantly down on any growth targets set last year, the knockon effect to the economy, particularly in terms of employment, is devastating. As an association we need to and are facing these many new challenges but the real unknown is certainly the government’s ability to tackle the issues preventing growth in our economy.
Udo Hänle, head of Production Integration and Pilot Plant, “the use of this state-of-theart computer tomography system is a major step forward for us as it will help us to improve the quality of our products even further.
We can now analyse our prototypes in minute detail without having to dismantle them first. The new system allows us to examine our vehicles in a way that wouldn’t be possible with conventional, static computer tomography systems. Ultimately, this will enable us to integrate new technologies into a series vehicles even faster.”
Analysis of internal structures
Michael Koch, head of Material and Process Analysis, adds, “we’ve been using CT and X- ray scans to check vehicle parts for many years, but this latest system takes quality assurance to an entirely new level. We can now analyse our vehicles right down to micro-metre level.”
This degree of detail is required for a range of reasons, for instance to check welds and punch screw connections, and to verify body condition before and after painting, where extreme temperatures can affect adhesive bonds. Findings from the scan are then used as a basis for making targeted modifications to series production.
The scan itself is performed by four coordinated robots. Once the vehicle is in position in the system, the robots move around it. Working in pairs, they send X-rays through it and across to their counterparts. The data they collect is then put through a specially developed computer program that calculates a multilayered, three-dimensional image. This forms the basis for a detailed analysis of the internal workings of the vehicle, offering information on objects as small as 100 micro-metres – approximately the width of a human hair.
Engineers are currently carrying out research to establish how far Artificial Intelligence might be used to evaluate findings. By processing large amounts of data, the software can learn the many different patterns that occur, link individual items of data and gradually evaluate findings automatically.
Two years of development work
BMW Group engineers and the Fraunhofer Development Centre for X-Ray Technology (EZRT) spent two years developing the new system, which is the only one of its kind in the automotive industry.
Philipp Janello, project manager at the BMW Group, explains: “Working with X-ray specialists and plant engineers, we were able to enhance the software of the test system with the help of comprehensive test measurements carried out on the vehicle body.” The result is a customized system that meets the requirements of the BMW Group.
Around 2,200 exhibitors are expected, well over half of them from outside Germany.
According to the organisers, EMO exhibitors have responded well to the early bird discount, which runs until October 15 this year. “Not only does it provide planning security, it’s also a great offer – especially for companies with large stands,” explained Welcker.
Smart technologies driving production
The theme of EMO Hannover 2019 will be Smart technologies driving tomorrow’s production! This shifts the focus onto the development and implementation of new Industry 4.0 functions. The special IoT in Production show, for example, will be presenting a range of solutions – from individual machines up to cloud-based systems. The theme will also be highlighted in a new area for individual control technology, software and automation technology exhibitors.
Carl Martin Welcker, CEO and President of Alfred H. Schütte GmbH in Cologne, representing EMO Hannover as its General Commissioner.
EMO Hannover – traditionally the largest innovation platform in the industry – will, however, also be showcasing the latest developments in the full range of metalworking machining processes, from additive manufacturing through to metal cutting. “Beyond networking and software-controlled production processes, the industry is still very much about metalworking hardware; workpieces still have to be processed in the conventional way to create an end product. EMO Hannover will also be showcasing the full spectrum of equipment,” explained Welcker. It is aimed at international customers from the entire metalworking and processing industry such as the automotive and parts supply, mechanical and plant engineering, electrical and aerospace industries, plus fields such as medical technology and many others. Hannover will be the hotspot for all of these in September 2019.
In addition to the wide range of exhibitors, EMO Hannover also offers a wealth of special events, forums and conferences staged by EMO organiser VDW (Verein Deutscher Werkzeugmaschinenfabriken –
German Machine Tool Builders’ Association), its business partners and numerous exhibitors. At the last EMO Hannover, the online calendar featured over 600 additional events. The overall programme makes EMO Hannover an important networking and knowledge transfer get-together for production experts from all over the world.
Job shops don’t have the luxury of scrapping multiple parts to refine a program. They need the first part to be a good part, but achieving this goal has become a bigger challenge as designers have increased part complexity to take advantage of expanding machine capabilities.
“Job shops have to keep pace with new control technology to keep scrape rates low,” says Gisbert Ledvon, TNC Business Development Manager, Heidenhain Corporation. “Continuing to use outdated controls for complex parts is like Einstein’s definition of insanity. If you expect different and better results, then explore the new Control and CAD-CAM technologies showcased at IMTS 2018.”
IMTS 2018 – The International Manufacturing Technology Show, which runs from Sept. 10 – 15 at Chicago’s McCormick Place, is the industry’s premier resource for connecting with control and software providers. Visitors can explore technology not only in the Controls & CAD-CAM Pavilion, but also in the Additive Manufacturing, Quality Assurance, Metal Cutting and Fabricating & Lasers Pavilions, as well as HANNOVER MESSE USA.
“CNC controls are an integral part of the digital thread that extends from cutting tools to ERP systems,” observes Peter R. Eelman, Vice President – Exhibitions & Business Development at AMT – The Association For Manufacturing Technology, which owns and produces IMTS. “At IMTS 2016, exhibitors were mostly talking about connected controls. At IMTS 2018, visitors can experience connected manufacturing – from design to part as never before.”
While controls are becoming easier to use, they’re also becoming much more powerful. “The controls graphic interfaces, applications and connectivity have expanded their functionality so operators can make intelligent decisions and take immediate action on the shop floor,” says Eelman. “Attending IMTS provides visitors with a rich opportunity to interact with the digital world of manufacturing and see how these capabilities can improve results in their operation.”
CNC controls are at the hub of the digital thread that extends from cutting tools to ERP systems. Look for a multitude of connectivity demonstration at IMTS 2018, such as those from Heidenhain featuring its State Monitor.
Connected Controls
Being able to load a part file or program into a CNC via the USB port was a good advancement for its time. Now, controls connected to CAD-CAM systems allow the operator to access part files, data and set-up sheets without ever leaving the machine and do so in a secure environment.
Of course, personnel working remotely from the CNC, whether in the engineering or QC department or managers at another facility, also want to capture, analyze and act on CNC-related data. Traditional types of data available from CNC controls includes machine status, current program running, spindle speed, availability, utilization rate and errors. Non-conventional data sources include tooling, workholding and discrete machine parts such as pumps, motors and encoders.
“IMTS visitors will notice that control manufacturers have placed a greater focus on importing more data into the machine control via MTConnect-enabled devices,” says Ledvon. “Correspondingly, they have developed software applications that graphically present information so shop owners can more easily make good decisions.” For flexibility, information can remain strictly within a user’s firewalls, can be accessed via the cloud or accessed from both.
IMTS visitors will also notice that machine controls now enable operators to switch the NC program between the desired functions. This gives job shops the freedom to decide how and when they want to combine machining methods, an important development necessary to keep pace with the expanded functions available from 5-axis mill turns. Other improvements include connecting controls to vision systems that can compare the current image to a reference image and spot any deviation from a perfect setup.
“It functions much like the face recognition feature of your iPhone. If something doesn’t look exactly right, the control will find it,” says Ledvon. Examples include missing hole for the next threading application, broken drill in the part, part not clamped correctly in a vice or on pallet, wrong engraved part number on the part and wrong part on the pallet.
New capabilities of the Heidenhain TNC 640 control include the ability to import a part file, call up a 3D model, zoom and rotate the display using touch screen controls, select portions of the file to modify and have the controls automatically generate new code.
Touch for Continuous Improvement
While machine learning and artificial intelligence may ultimately minimize the need for humans to interact with controls, those developments remain over the horizon. For the coming decades, Heidenhain believes that engaging operators is essential for optimizing the machining process.
As a result, new control capabilities include the ability to import a part file, call up a 3D model, zoom and rotate the display using touch screen controls, select portions of the file to modify and have the controls automatically generate new code.
“If operators discover a missing part feature or need to modify the cutting path to avoid a collision, they can make changes without engineering support,” says Ledvon. “Operators working on second or third shift tell us how they finished a batch of parts on time or minimized the number of bad parts because of new control capabilities. Operators also provide immediate feedback to CAD-CAM and quality control systems.”
Ledvon further notes that those working on smaller production runs need to cut the first part correctly. “New control technology makes cutting more accurate and shops more productive by eliminating sources of waste, such as cutting multiple bad parts in order to fine tune the cutting path,” says Ledvon.
AMT’s Eelman adds that, “the future is now for the connected manufacturing world and coming to IMTS provides the venue for interaction and engagement with the technologies that will shape the future of manufacturing.”
First came smart phones, then intelligent cars and houses. Now, visitors to the Metal Cutting Pavilion at IMTS 2018 – The International Manufacturing Technology Show, can experience the explosive productivity growth possible with smart, connected machining centers.
“The conversations at IMTS have changed from spindle speeds and traverse rates to how to deliver pertinent information so job shops and manufacturers can better manage their assets,” says Marlow Knabach, Executive VP, National Engineering, DMG MORI USA. “To start the conversation, exhibitors in the Metal Cutting Pavilion at IMTS will demonstrate smart machines with the ability to monitor critical elements, such as spindle bearing temperature, spindle vibration, ball screw temperature, coolant level and tool wear to identify potential sources of downtime before they occur.”
“Lean companies need smarter approaches, and connecting with the exhibitors in the Metal Cutting Pavilion at IMTS 2018 will help them develop new strategies for more efficient part manufacturing,” says Peter R. Eelman, Vice President – Exhibitions & Business Development at AMT – The Association For Manufacturing Technology, which owns and produces IMTS.
In addition to connectivity, Eelman says that technology highlights from the Metal Cutting Pavilion exhibitors at IMTS 2018 include more collaboration between CNC and automation providers, more process integration to create multi-tasking machines and more powerful software and user-friendly CNC controls.
Information for Everyone
Achieving overall equipment effectiveness (OEE) rates greater than 80 percent in job shops, is a greater challenge compared to higher volume manufacturing. Traditionally, job shops could not take advantage of software-based systems for automation and process monitoring or Ethernet- based communication protocols because the cost and complexity were too prohibitive.
“Communication protocols and software-based systems process monitoring enable considerable cost and time reductions in total system operation,” says Paul Gray, Ph.D., Manager for Path Planning, Front-end Design and R&D at Hurco. “Smaller job shops and those with high-mix, low volume parts who attend IMTS 2018 will find that the benefits of intelligent machining and automation are within their reach.”
Knabach adds that, “the return on investment for machine monitoring is so pronounced that I would challenge anyone if they could not obtain a return on investment within one year.” ROI happens quickly because monitoring usually reveals an OEE much lower than expected. “Understanding utilization rates, causes of common alarms and premature tool wear and so much more are available with a connection, especially since the growth of devices compliant with the MTConnect standard.” For companies who are not prepared for a cloud-based operation or cannot do so because of industry regulations (e.g., defense contractors), he notes that connected machines, devices and systems can operate entirely behind a company firewall.
Hurco will showcase a 3-axis machining center in their automation quadrant. The VM10i features a small footprint with a large work cube. No other mill packs as much productivity into such an efficiently designed package. The VM10i offers a maximum load capacity of 1,499 lbs. and will partner with a collaborative robot to create personalized brass coins for booth visitors.
Automation & CNC Integration
In addition to Industry 4.0 machine and device monitoring demonstrations (likely numbering in the hundreds at IMTS 2018), exhibitors will show how enhanced data exchange is essential for intelligent manufacturing. One example would include a CNC, a robot for automated part loading/unloading and a CMM, all connected to create a closed-loop system that automatically updates tool offsets. Easy part change-over is another.
“Automation integration used to be more expensive and difficult because you had simple I/O connections and needed to reprogram a PLC when changing parts,” says Gray. “CNC manufacturers and automation providers have been working together to provide seamless integration between the CNC control and the robot control. With software systems talking with each other over an Ethernet connection, users can now bundle all aspects of the job together. We’ve created a new level of flexibility and simplicity in part change-over in production cells.”
Hurco will demonstrate automation integration as part of its 50th anniversary celebration at IMTS 2018. A collaborative robot will 3D scan visitors’ faces, generate a solid model from that data to create a tool path and then either a 5-axis CNC will cut the head from cylindrical aluminium stock or a 3-axis CNC will cut the form into a brass coin. Both CNCs will be connected to fully automated robot systems that are coordinated by a centralized job management system.
Focusing on automation, a collaborative robot will scan visitors’ faces and generate tool paths for Hurco’s 5-axis VMX30Ui to cut a 3D head from cylindrical aluminum. The VMX30Ui trunnion table machining center will be connected to a fully automated robot coordinated by a centralized job management system.
Process Integration
Like automation, process integration continues to fuel the technology needed to remove manual intervention to drive up OEE rates. Lathes and mills have morphed into a single machine platform, the mill turn.
“Machine manufacturers are now adding more capabilities. Examples to look for at IMTS include 5-axis CNCs that can also gear hob, gear skive and grind,” says Knabach. “By incorporating inspection software and a touch probe, the machine can confirm part profile before removing it from the machine, eliminating the need to re-orient the part if it requires additional processing. By reducing the number of times a part is handled and fixtured, process integration inherently increases part accuracy and improves OEE.”
In the age of digitization, DMG MORI will bring to IMTS the CELOS Ecosystem which includes 26 CELOS apps for tooling, machine configuration and digital interaction in the workshop available. With CELOS, customers receive intuitive, consistent solutions as an integrated basis for paperless digital production.
These multi-tasking machines work well for companies that have limited floor space and for those who don’t need a dedicated gear hobbing/skiving machine, such as R&D or MRO centers and job shops serving the transportation industry.
Controls
CNC and control manufacturers all want to improve the customer experience, and the ways to achieve that are as nearly as diverse as the exhibitors in the Metal Cutting Pavilion. AMT’s Eelman says that, “the manufacturing industry is now being influenced by software experts who bring new perspectives. More commonly, entering G-code is being replaced by importing and editing the digital model, while graphically intensive controls engage younger generations as they enter the workforce.”
“Innovations at IMTS 2018 include solid model import, a technology that directly imports 3D CAD models to the CNC control,” says Gray. “Users don’t have to punch in numbers or scroll through screens. They just click on the parts of the CAD model that they want to cut and solid model import automatically creates the data blocks. It drastically reduces programming time.”
Peter R. Eelman, Vice President – Exhibitions & Business Development at AMT – The Association For Manufacturing Technology, which owns and produces IMTS.
Gray notes that editing part features can now be as simple as selecting the geometry on a touch screen and the corresponding code (NC) or data block (conversational) automatically appears without the user wasting time searching through lines of code to find what they need to edit.
Knabach adds that, “today’s HMIs engage the operator by presenting information that is relevant to the operation of the machine at a specific point and time. Multi-touch monitors feature icons, while a series of apps help operators prepare, optimize and process production jobs – and of course, manufacturers continue to develop new apps.”
Knabach also reinforces Gray’s earlier message, saying, “machine manufacturers now design controls so that they connect with higher-level enterprise and other production systems via standards such as MTConnect. Holistic integration of CNCs into the rest of the organization is now our standard approach so that we can harness the advantages of Industry 4.0.”
Eelman says that staying current with new metal cutting technology has a much broader focus at IMTS 2018. “The CNC still forms the heart of machining, but users that want high utilization rates will evaluate CNCs in the context of a digitally connected production cell that includes automation, CMMs, enterprise systems and other devices. With the Metal Cutting Pavilion and nine other technology pavilions at IMTS 2018, visitors have an unmatched opportunity to evaluate all these new technologies in one place.”
Analysis of internal structures
Two years of development work
