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Procedia CIRP 59 (2017) 156 – 159
Abstract
Quality management of machine tools is the key to reducing downtime of customers’ machines and the manufacturers’ service cost. This paper
introduces DMG MORI’s systematic workflow from designing, procurement, manufacturing, and acceptance inspections to the delivery of
machines, which contributes to improvement of machine quality. Two quality management systems, one for before shipment and the other for
after shipment, are described in this paper. Various workflow systems, data analysis, remote monitoring, continuous Kaizen approaches are
integrated in the systems. However, defects of machines cannot be completely eliminated, so proactive maintenance and strong service
networks are vital for business success. Especially, proactive maintenance is favorably accepted in the industry as a solution to minimize
machine downtime and the repairing cost. This paper introduces various sensing technologies to improve the functions of proactive
maintenance.
©©2016
2016 The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V.
B.V. This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of the Programme Committee of the 5th International Conference on Through-life Engineering Services
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
(TESConfunder
Peer-review responsibility of the scientific committee of the The 5th International Conference on Through-life Engineering Services (TESConf 2016)
2016).
2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the The 5th International Conference on Through-life Engineering Services (TESConf 2016)
doi:10.1016/j.procir.2016.09.029
Makoto Fujishima et al. / Procedia CIRP 59 (2017) 156 – 159 157
The key to providing customers with machine tools which Fig. 1 shows how the processes of the manufacturing
do not break down is to improve quality during the production management, quality management, and acceptance inspection
processes. This is the common target for most of the divisions are combined. These processes and the quality of machines
in the entire plant including development and manufacturing tools are all managed at one central system by computers. Fig.
divisions. The following are the items to be achieved. 2 shows the flow of assembly work in a vertical space
1. Common items utilizing the 3D model and BOM system to create standard
Lean manufacturing procedures for assembly work and test procedures.
Education/training
PDCA cycle 2.1 Quality management before shipment
2. Design section Quality inspections are conducted to detect problems
Design review including potential problems at the factories before shipment
Design verification to prevent problems from occurring after machine tools are
Customer point of view evaluation delivered to the customers’ factories. Fig. 3 shows the flow of
3. Manufacturing section the product inspections including the positioning accuracy test,
Before shipment quality management cutting test, product inspection, running test, and shipment
Kaizen inspection.
Inspection In the quality inspection processes actions for improvement
4. Procurement section are continuously taken, contributing to the quality
Supplier management improvement of machine tools.
Acceptance inspection 㻵㼚㼢㼑㼚㼠㼛㼞㼥㻌 Digital picking 㻼㼞㼛㼏㼑㼟㼟㻌
Process management 㼙㼍㼚㼍㼓㼑㼙㼑㼚㼠
Cost management 㼙㼍㼚㼍㼓㼑㼙㼑㼚㼠
VPS䠖Virtual product
Parts preparation
Delivery management simulator Operation
indication
Barcode
This paper introduces approaches to the above-mentioned Interference check reader
contents as a machine tool manufacturer.
Standard Transfer
Process managem
management
me t
me
2. Quality management at the factory
DMG MORI has 13 main factories in seven countries. This Operation
recor
global production system, with factories in Europe, the U.S.A.,
and China, as well as four factories in Japan and three in ORiN
Feed back
Germany, reduces risks of volatile currency exchange rates,
and enables optimal machine tool delivery for the customers Fig. 2 Utilization of Design data
worldwide in terms of transportation costs and lead time.
In-process inspection Positioning accuracy test Cutting test
Additionally, high accuracy magnescales and laser scales are
ISO standard test Cutting accuracy test
Self inspection by
produced in Isehara, and Taiyo Koki's grinding machines are the assembly
personnel
produced in Nagaoka. At the factory in Iga, the largest one
among the 13 main factories, medium-size and large-size
machine tools are manufactured. The quality management
divisions in Iga, which consists of two divisions: the before Shipment Shipment inspection Product inspection
100-hours running operation
shipment quality management division and after shipment Inspection of packaging Overall running operation of 100 specifications,
and bundled items at hours in total, covering all functions,
quality management division. The before shipment quality shipm
shipment roces
oces
oc
o ce
c e
essses
processesses
se embedded software
and safety
management division is responsible for inspecting machines
before shipment to provide customers with high-quality
machine tools, whereas the after shipment quality
management division is responsible for improving the quality
of machine tools after they are installed at customers’ factories. Fig.3 Product inspection
158 Makoto Fujishima et al. / Procedia CIRP 59 (2017) 156 – 159
The coolant level in the tank can be easily detected with this
ATC, Magazine Chattering control Balance monitoring/ control
sensor. That is, monitoring the clean tank and dirty tank
Preventive Maintenance 䞉XYZ Vibration sensors
䞉 Motor load and torque 䞉Motor load 䞉SP Balancing data enables us to predict when the filter between the tanks needs
䞉Bearing temp. and vibration data
B Axis automatic
rotation adjustment
cleaning or replacing. The timing is when the difference
䞉 Servo data from motor Hydraulic management
drivers
䞉 Pressure between coolant levels of both tanks becomes higher than a
䞉 Controller alarm
Power monitor 䞉Contamination of oil
certain level.
䞉Power consumption
(Voltage & current) Oil cooler management Reducing the power consumption of a machine tool is one of
Remote monitoring 䞉 M/C body temp.
䞉Alarm signal 䞉 Oil Temp. the most important themes. The authors have studied power
䞉 Atmosphere temp.
䞉Operation monitor
䞉sensing data
䞉 Motor load saving and experienced that power consumption was actually
䞉 Controller alarm
References