DMG/Mori Seiki global expansion

The DMG/Mori Seiki annual Open House held at Gildemeister AG's Pfronten, Bavaria, Germany site is now the event where not only latest machine tool models are unveiled, but also where details about the progressing partnership between DMG (Gildemeister AG's sales and service organisation) and Japanese machine tool builder Mori Seiki are revealed. The pair have sales of more than £2.75 billion, according to their most recent annual reports. For comparison, the global machine tool market in 2011, according to Gardner Publications' annual survey, was £59 billion, which means, together, DMG and Mori Seiki account for approaching 5% of global consumption. (Some caution must be exercised, due to the changing nature of exchange rates used in calculating these figures.) DMG/Mori Seiki itself is claiming it will have a worldwide market share of 6% of 2013's estimated €70.1 billion – global growth of 7.6% is forecast for 2013; better than 2012's 5.2% . More impressively, a market share of 39% for China and 55% for Canada and South America is foreseen by the pair for this year. And this year, Dr Rüdiger Kapitza, Gildemeister AG chairman, offered that the two companies would reveal 27 innovations – six at this Open House, with 16 more at EMO, with still yet more at other events during this year. Internationalisation and the joint production of machines across the two companies' global facilities will be an increasing theme, opened Dr Kapitza. This will reduce the additional costs incurred in transporting machinery long distances from production plant to customer – put at an additional 15% and which approximately halves typical gross margin. The pair have 17 machine tool plants globally, with a further two in construction – one a DMG-led investment in Russia; the other a Mori Seiki-led investment in China. In fact, Mori Seiki has also only recently opened a manufacturing plant in Davis, California. The Russian factory, in Ulyanovsk, on the Volga River over 500 miles east of Moscow, which comes on stream this year and next, will produce DMG machines CTX 310 and 520 ecoline lathes, DMC 635 V and 1035 V ecoline VMCs and DMU 50 ecoline 5-axis VMCs. It will have a capacity of 1,000 machines/year, when completed. CHINA INVESTMENT The new Mori Seiki factory in China, in Tianjin, will produce NHX 4000 and 5000 horizontal machining centres, beginning Q4 this year, and will have a capacity of 100 units/month, in the first phase. Interestingly, due to restrictions, the accuracy of these machines will be 'downgraded', noted Dr Masahiko Mori, CEO Mori Seiki, but, he added, they would still be capable of making automotive components. This plant will also procure and machine cast iron to supply this to other DMG and Mori Seiki plants globally. Also in China, DMG is to expand its plant in Shanghai, adding DMU 50 production this year to the CTX 310 and 510 ecoline lathes, DMC 635 V and 1035 V ecoline VMCs and MillTap 700 production already ongoing. With a current capacity of 2,000 machines/year (exporting 50%), after expansion the plant will be capable of making 4,000 units/year. In Japan, Mori Seiki will expand production at its Iga plant, adding DMG DMU 50 production this year. Other expansions will be in Switzerland, where the new DMG/Mori Seiki Europe HQ and technology centre is being be established, with a similar set-up in Japan, in Tokyo, where 30 machines will be on view (including 10-15 DMG models), plus a new Mori Seiki Magnescale factory being built in Germany, at Wernau, near Stuttgart. Magnescale position measurement technology, used in the semiconductor industry, as well as machine tools, is now certified for use with Siemens CNC technology, hence the decision to build this new factory. PARTNER PRODUCTION Regarding production of one company's product in the factory of another, Mori Seiki's NHX4000 is already assembled in Pfronten – with the NHX5000 joining it this year – while the unveiled NLX2500 SY/700 is also to be made in Europe, in Bergamo, Italy. Looking at growth sectors for the companies, Dr Mori believes that there is a "huge chance for us to expand our market share" in the medical sector. Not only is this a growing sector, expected to grow 8% annually over the next five years, but, because all of the parts are new, companies are looking to modern technology such as mill-turn as the production platform, he offers. Machines such as the NTX1000 mill-turn are particularly suitable, it was indicated. Mori Seiki's top man also sees a strong demand for the CTV 250 DF pick-up spindle VTL machine, in particular for constant velocity joints in the auto industry. This DMG technology would be introduced to Japanese automotive manufacturers, he said, and, with it accepted there, it would then be an automatic step to see the technology employed in Chinese automotive factories. "I am quite excited about introducing this innovative CTV technology to Japanese and mainland customers," Dr Mori offered. Underlining this Japanese market access for DMG technology via Mori Seiki's connections, Dr Mori also highlights that, for this event, more than 20 top aerospace manufacturing specialists travelled from Japan, with DMG FD technology a particular target (5-axis machining, combined with vertical turning; 18 models now available) – Pfronten is the headquarters of the DMG aerospace excellence centre. In fact, Mori Seiki already sells five to six machines a month into the aerospace sector in Japan, as well as the USA, offers Dr Mori. Launched at the January event were six world premières and three European premières, the latter from Mori Seiki. The world premières were: DMC 80 H linear (HMC), which follows last year's successful 60 H linear introduction; DMC 65 FD monoBLOCK (5-axis mill-turn); DMU 125 FD monoBLOCK (5-axis mill-turn), which also includes a grinding capability; CTX beta 2000 (turning centre); NLX 2500 SY/700 (turning centre); Dixi 210 high precision 5-axis horizontal machining centre. On the European premières front, these take in three NLX turning centres – NLX1500 Y/500; NLX2000 SY/500; and the NLX3000 Y/700. Another highlight is the Special DMU 75 monoBLOCK 5-axis machining centre, supplied as a complete package for €209,900. Heidenhain iTNC 530 HSCI, 18,000 rpm spindle, 60-tool magazine and machine protection control are included. Returning to the Dixi machine, DMG already takes component parts for machine tools from Mori Seiki factories, but, in a somewhat larger supply of one company to another, Mori Seiki's latest Dixi 210 high precision 5-axis machine is based on a DMG DMU 210 machine from Pfronten, but with an accuracy that is three times better, claiming volumetric accuracy of within 35 microns in its 1,850 by 2,100 by 1,250 mm working volume. This characteristic is put down to the 500 hours of slideway scraping, which results in highest built-in geometric accuracy. Temperature monitoring and control also support this achievement in the workplace, of course. The benefit of using the DMG design as a base is that the additional cost is put at only about 30% by Dr Kapitza. Moving to larger matters and the XXL machine highlighted and in build at Pfronten – the DMU 600P – is capable of 5-axis machining of parts weighing up to 75 tonnes. The two-pallet machine is some 41 m in length, although the working area is 18 by 4.8 by 1.5 by 2 m in X, Y, Z and W axes. It is destined for a Swiss customer. Moving to ultrasonic machining, and this capability can be fitted to all of DMG's machining centres. An example of its application, shown at Pfronten, is the repair of a damaged composite helicopter blade. This takes in the on-machine scanning of the damaged area, followed by the machining of the surrounding area, using special ultrasonic tools, which can be toolchanged, like standard tools. These tools remove a complete layer of composite material – several closer to the damaged area and progressively fewer as distance from the damage increases – producing a series of elliptical areas. A problem in such repairs is the reluctance of the surface to bond. With the DMG process, a plasma is generated, via the ultrasonic head technology (patent applied for), which is used to activate the surface. In this particular application, hundreds of hours are saved. The machining of composites more generally is a target, with the process offering minimal delamination, higher tool life and faster processing. Trimming, milling and drilling of parts are possible, with several machines already installed. Portable machines are also a possibility, to support field repairs of aircraft and boats. COMPETITION UNVEILED Finally, the 5-axis Machining Expert competition, operated in cooperation with German technical institution IFW, is open to "top international DMG/Mori Seiki customers" and focuses on the complete process chain, from idea through to production. The registration deadline is 1 June this year, with judging taking place in August and the presentation made at the EMO exhibition in September. The competition is modelled on the Mori Seiki Cutting Dream competition. And looking ahead to the forthcoming EMO exhibition – Hanover, 16-21 September – innovations to be present, and heralded at the January Open House event, will number 16. They are grouped under three brands – DMG (10), DMG/Mori Seiki (3) and Mori Seiki (3). Dr Kapitza offers that the two companies' machine designs will be seen to be coming closer together at the show, too. Apart from specific machines, themes at the event will include life-cycle services (taking in the increasing use of telecommunications), automation (particularly relatively simple solutions) and energy efficiency (30% more efficient is the target for its machines). In fact, energy efficiency is taken further by DMG than by other machine tool companies, because Gildemeister AG is involved in renewable energy generation and storage via its Energy Solutions business. This includes its SunCarrier solar energy array carrying system, its WindCarrier wind energy system and its CellCube energy storage solution. The company has, in fact, recently set up an energy park at its Bielefeld site in Germany to underline the benefits of the technology. Extended article from here World premieres [] The DMC 80 H linear is offered in many versions, including with an HSK-A100 tool taper and 430-Nm spindle..... [] DMG/Mori Seiki has added a turning capability to its DMU 125 monoBLOCK vertical machining centre, naming the new machine the DMU 125 FD.... [] DMG/Mori Seiki is now offering the DMC 65 monoBLOCK vertical machining centre in a version that has turning capability – the DMC 65 FD monoBLOCK [] DMG/Mori Seiki's CTX beta 2000 has a 600 mm diameter and 2,000 mm turning length capacity and is positioned between the smaller CTX beta 1250 and the large CTX gamma 2000 [] The Mori Seiki NLX2500Y/700 is now produced in Europe, at Gildemeister Italiana, offering shorter delivery times.... [] The new DIXI 210 P from DMG/Mori Seiki features a volumetric accuracy of 35 µm for the precise machining of large, heavy components.... Other product news [] DMG/Mori Seiki's DMC 60 H linear horizontal machining centre can now be equipped with an RS12 rotary pallet storage unit. .... [] Mori Seiki has given European debuts to three CNC lathes: NLX1500Y/500; NLX2000SY/500; and NLX3000Y/700 First published in Machinery, March 2013