Automation and digitization set the course

The scarcity of technical staff remains the biggest challenge for metalworkers. Yamazaki Mazak therefore supports its customers with technology that enables them to produce smartly. On the one hand, by automating repetitive work. On the other hand, by focusing on digitization, so that even the programming of small series becomes particularly profitable and any problems can be solved remotely. Moreover, the high-quality machines it supplies for machining and sheet metal working take sustainability into account: from design, development, production to use. This ensures you the lowest possible cost per piece.

"Automation today goes much further than before," opens sales manager Benelux Hugo Verlaak. "Not only workpieces are now loaded automatically, we can also replace pallets, claws and collets. The autonomy of machining machines went enormously in crescendo because of this, so that many more spindle hours are made." Classically, a robot is set up next to the machine for this purpose, but it can just as easily be done with a more mobile solution. "For example, the material to be machined can leave from a central supply point in the workshop to the various work stations using AGVs. We showed a solution from Kumatech for this at our Open House days. A way to excite our customers and think about what their workshop of the future could look like."

Easier sorting out

Nor does laser cutting escape the trend toward greater automation. Tim Depijpere, sales manager Benelux for Mazak Laser: "The same challenges of a lack of personnel play a role here. We try to solve that by delivering machines that autonomously deliver a high output. During the last EuroBLECH we presented our Laser Beam Shaping technology that ensures a straight cut and a wide joint, so that pieces no longer get stuck in the skeleton and can therefore be sorted out automatically. Especially for suppliers who process a wide variety of pieces, we can take this another step further. We are also focusing on ease of use by keeping the threshold for operating laser cutting machines as low as possible. The operator can make adjustments very intuitively if necessary. For laser cutting machines, programming is done almost entirely offline. "A process that is now fully digitized. The software can realize the complete deployment from a 3D drawing and indicate how to cut and nest the pieces. Mazak is resolutely sailing an open course in this regard. We give our customers the freedom to choose the best software for their needs and ensure that everything is automatically integrated into our machines," Depijpere adds.     

Also automate programming

For machining, this is a bit more difficult since there are many more parameters at play. Nevertheless, Mazak is showing itself to be the best student in the class in that area as well. "With the new Smooth AI control, programming can also be largely automated. Even with limited machining knowledge, time can thus be saved up to 80%. This control is already standard on our five-axis machines but will be rolled out across the entire range in the coming years. "The pinnacle of this evolution is working with digital twins. If both the part and the machine exist virtually, simulation software can always provide the best possible machining techniques. At Mazak, all that is integrated directly into the control.

Verlaak clarifies, "Metalworkers don't need any additional simulation software or post-processor. Everything happens one-to-one. We will see this evolve even further in the coming years through toolmanagment,machining data and workpiece calculation. These are again improvements that allow the user to use his machine even more efficiently."

Machines that help save energy costs

And whoever says efficiency naturally thinks of sustainability. A topic high on the agenda everywhere now that energy costs have risen so much. Metalworkers also saw their bills rise significantly. "Even with a few small machines, you quickly find yourself at 3,000 euros per month. Mazak is helping its customers with this by developing sustainable production technology. A fiber laser source is the perfect example of this, because the energy consumption is much lower than with a CO2 laser, even though the power is higher. This has everything to do with the energy efficiency of the diode technology. But a lot of adjustments have already been made to our machines in recent years, resulting in a 22% reduction in CO2 emissions by 2021. Think of shorter cycle times, new cooling units, smart LED lighting, improved accumulator technology... Everything is monitored in the Smooth Energy Dashboard," says Depijpere. 

IConnect: all the data on your machines

After all, knowing starts with measuring. That is also the basic idea behind Industrie 4.0. Mazak has translated these principles for its clients into Mazak iConnect. Via a SIM card, machines can access Mazak's own cloud. "A portal where customers can find out everything about how their machines are performing (cutting hours, spindle hours...), but also have access to all the information (service intervals, spare parts...) and documentation. The intention is to help customers get the most out of their machines in this way. Moreover, this way we can also support them with extensive remote assistance, so that production standstills are solved as quickly as possible. After all, at Mazak we consider service of paramount importance. That is why the European Parts Center will soon be further expanded so that we can meet customer requests even more quickly," concludes Verlaak.