A flexible mix of internal production and contract manufacturing
In addition to the turning and milling machines of the CLX, CMX V and CMX U series developed and produced at the site and the automation solutions the company develops itself, metal cutting is one of the fundamental pillars of its success. “Beyond meeting our own needs, our production facilities in Pleszew also act as a metal cutting service provider for the DMG MORI production network,” explains Dr Michael Budt, the Managing Director.
Doubling capacity by 2020
Around 50 networked machine tools, the majority from the group’s own “DMG MORI family,” are in operation around the clock at the moment in order to meet the enormous demand. Over 1,200 prefabricated machine frames and hundreds of sub-assemblies and components currently leave the plant on their way to the sister companies DECKEL MAHO Pfronten, DECKEL MAHO Seebach, GILDEMEISTER Drehmaschinen in Bielefeld and other group locations.
And demand is on the rise. By 2020 the capacity of the FAMOT plant will be virtually doubled to 2,000 DMG MORI machine tools and around an additional 2,000 prefabricated machine frames. To achieve this, DMG MORI will invest approx. 60 million Euros in the renovation and expansion of the site in Poland by the end of 2018. Another 20 million Euros have been budgeted for future automation projects.
The age of digitization
A considerable part of the future FAMOT project is the digitization of the entire added value chain. “What belongs together we put together digitally,” stresses the General Managing Director Zbigniew Nadstawski. He refers here in particular to the connection to the IT infrastructure of DMG MORI. All added value levels including internal workflows, systems and (automated and manual) process steps had to be seamlessly networked at the same time: From order receipt in sales through to maintenance management, and from integral production planning through to the in-house MDC / PDA software for monitoring key parameters.
“And above all we had to make our personnel digitally fit,” stresses Zbigniew Nadstawski. The management sees people essential for concluding such a mammoth task successfully. They are convinced: “Our employees are crucial for the success of the digitization.”
Declared goals include fast, efficient and secure production processes and an overall sustainable increase in productivity, quality, transparency and response capacity. The specifications also encompassed the requirement for linking existing stand-alone solutions and new software systems into a coherent agile production network.
Digital planning solutions from ISTOS
On its way to achieving these goals, FAMOT relies on the competence of its digital sister companies within the Group. These include DMG MORI Software Solutions (in particular with its CELOS portfolio) and WERKBLiQ (with its web-based maintenance and service platform). ISTOS GmbH with its modular applications for end-to-end production planning is of special importance as well.
All parts of the system (such as order management, capture of shop floor data overall data management) operate autonomously on the one hand, but are all linked via the so-called SERVICE BUS on the other. This takes on the role of an intermediary via which all connected applications are on a uniform data set and communicate bidirectionally.