Lean Production
Lean design - the concept, the machinery, the automation. With the new XS 211 machining center concept, MAG Powertrain is setting new standards in the area of “lean” production. 58 XS 211 machines are being used by GM for machining its transmission bell housing, transmission case, transmission upper valve body and transmission lower valve body components. Prior to the start of the project, the development engineers set a challenge for themselves: to develop a production system that achieves the highest possible technological quality at the lowest possible cost. The result: a blend of proven technology and innovative workpiece management.
The Basis of Production
The XS 211 machining centers form the basis of the production systems, in conjunction with the newly developed automation concept. The machines have been specially tailored to meet the customer's requirements. In its role as key supplier, MAG Powertrain is responsible for the complete mechanical production, from the process design and tools up to the automation system. The benefit for the customer is clear:
Since the scope of delivery comprises all the production machines, the various components can be precisely coordinated with each other. This ensures optimal utilization and excellent production results from the system. To make the machining centers even more attractive in terms of price, the machine was reduced to those components that are absolutely technically essential in line with the customer's specifications. To this end, it was important that the MAG Powertrain engineers maintain the MAG Powertrain quality standards.
The result:
- Extremely efficient machining centers
- High production precision
- Very attractive price
- Low machine width
- Compact design
- Three-point mounting
- Individually adjustable machine
- Quick commissioning process
- Cost-effective automation with front loading via roller conveyors
A System That Will Simply Floor You
Since the cost reductions are also to be transferred to the process, every aspect of the process design was analyzed. A floor-based automation system using conveyor belts was specially developed for the XS 211. The loading equipment, combined with the option to move the XS 211 worktable in the Z-axis, forms the core of this automation method. The machined workpiece is unloaded using an automatic swivel mechanism. By swiveling the automation unit to 180°, the machine can be immediately loaded again in a single operation. The workpieces are all supplied via conveyor belts. The advantage of this system is that the unloading and loading time can be reduced to a minimum. All the machining centers are loaded from their fronts, making it possible to easily intervene in the production process at any time.
Series Production to Order
The project started in May 2004. The objective: deliver the last XS 211 machines in June 2005. A new installation concept had to be developed to ensure that this tight schedule, which included all components of the project handling and completion, could be met. Assembling individual parts to form pre-assembled modules made it possible to considerably reduce the installation time. On the basis of this module-based installation method, the line-assembly concept was developed. This means that XS 211 machining centers can now be assembled, safely commissioned and installed at the customer's premises within a period of just ten days.
