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Automated machine tools

Enhanced productivity, better quality

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www.kuka-robotics.comEnhanced productivity, better qualityKUKA Roboter GmbH | MSM | Schuhbauer | 21.April 2015| Page3

The advantage of human workers

Flexibility

Sensitivity

Creativity

http://www.kuka.biz/�


Manual loaded machine tools

One worker per machine?Worker has to wait for the machine

One worker on many machines? machine has to wait for the worker



One worker, many tasks



The advantage of automation

Consistency

Reliability

Availability



Robot loaded machine tools

One robot on one machine



Robot loaded machine tools

One robot for several machines



ShorterDelivery time

ImprovedReliability

and Quality

No riskOf turnover

HigherThroughput

ReducedLabor costs

Reducedcomplexity

IncreasedValue of theWorkplace

UninterruptedManufacturing

Why should I automate

100% utilization of your machine tool potential: maximize your machine productivity by automation. Manufacture even complex parts with higher quality and reliability while reducing costs at the same time.

shut down10%

tools9%

waste treatment8%

maintenance15%

manpower35%

Invest14%

planning6%

others3%

manuell automatic

1,00% 0,50% 10,73%

0,50% 0,25% 4,84%

0,10% 0,05% 0,90%

Yield loss Revenue increase

Part output over 8hour shift

0

2

4

6

8

10

12

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

part

s pe

r 15m

in in

verv

al

Manualloading

Robotloading

Output on 8 hour shift with 90sec per part

050

100150200250300350

theoretical output at100%

robot output at99.995%

robot output at 98% manual output bestcase

m

part

s pe

r 8 h

our s

hift



Improved reliability / quality

manuell automatic

1,00% 0,50% 10,73%

0,50% 0,25% 4,84%

0,10% 0,05% 0,90%

Yield loss Revenue increase

Attention span of a human being ~ 20min

Attention span of a robot = 40.000 hours

Loss of attention ≙ mistakes ≙ lost money

Wrong processed parts caused by:

- Part placed incorrectly- Part poorly clamped- Part chipped during load, unload or storing- Manufacturing step missedWill not happen with robot handling.

Calculation example:Jobshop with raw part costs 5 Dollar, margin 0.3 Dollar 1 miss-processed part eats the margin of 16 good parts



Reduced labor costs respectively additional shifts

shut down10%

tools9%

waste treatment8%

maintenance15%

manpower35%

Invest14%

planning6%

others3%

Average lifecycle costs over 10 years. Source: Daimler

Labor ≙ 35% of life cycle costs

Labor costs in the Shanghai area rose by 30% in 2013

One worker can run multiple automated machines without the risk of machine waiting time

Machine can run overnight without worker present



Higher throughput

Worker productivity 63% to 84% (study by GEO/Fabrik des Jahres 2010 in Germany)

Robot productive 98% to 99.995% (Source: leading German car manufacturer)

Example: Machining time 90sec per piece3 x 3min per day for toilet 6 parts less producedlunch break 20 parts less produced“how was your weekend?” from a coworker 5 parts less produced

Productivity: worker 74% versus 98% of the robot at 90sec machining time automated cell makes 77 parts more per 8 hour shift.

Output on 8 hour shift with 90sec per part

050

100150200250300350

theoretical output at100%

robot output at99.995%

robot output at 98% manual output bestcase

manual output worstcase

part

s pe

r 8 h

our s

hift



Shorter delivery time

Example: new order comes in on Tuesday morning, it takes 5 hours to program the part, 40 hours to manufacture all ordered parts,

all parts will be ready for shipment • on Tuesday night the following (!) week in a one shift production (no weekend work). • on Thursday night in a two shift production (to late for shipment the same day)• on Thursday early morning in a automated three shift production (even with 3 additional hours to get the

automation ready)• 5 days earlier than one shift production• 1 full day earlier than two shift production or 2 days after order entry instead of 3 days

Regular work 1 shift / day. Big order need to work 3 shifts, but not enough worker lost order / customer

Robot work overnight without complain fulfilled order / happy customer



Uninterrupted manufacturing

As discussed on previous pages the robot needs no break’s and he has a MTBF (mean time between failure) of 40.000 hours (Source: leading German car manufacturer) with an average of 10 hours preventive maintenance per year. Otherwise the robot is continuously working and producing parts with a reliable part-to-part time. This generates a continuous stream of parts and therefore reduces the need for buffer stations between manufacturing steps.

Part output over 8hour shift

0

2

4

6

8

10

12

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

part

s pe

r 15m

in in

verv

al

Manualloading

Robotloading



Increased value of the workplace and replace unattractive workplaces

Short cycle time = Stressful

Long cycle time = boring

Shop floors are Hot

Dirty

Loud

Programming robots is Clean

Interesting

Considered high level work



No risk of turnover

Turnover of workforce generates high costs.

With robot automationWork becomes more attractive, leading to less desire of people to leave the companyRobots will not leave for a better paid job next door.



Reduced Complexity

Managing productions with hundreds of workers requires a lot of management.Planning for Sick Days Vacation Turn over Training

Managing a high volume of different parts (customizing) requires a high organization level and oversight in manual handling factories

Robots are trained and setup once for every work piece. Program can be recalled by using bar codes or program numbers. Intelligent gripper can detect / verify the part specification.



Customer specific cell example: KUKA hall 10 KR Quantec on DMG machine Processing of 2 different casting parts for KUKA Robot hand axis

Manual loading:2 shifts48min process time on the machine

600 parts per month

Robot loading:Third shift manless40min process time + additional tasks by KUKA robot

1080 parts per month

80% increase of machine output 8.000 production hours per year



Easy use

HMI: A graphical user interface allows even un-experienced workers to control the application



The past



The future



Outlook

Pressure on the part costs will increase further

Lot size will decrease because of customizing

Part complexity is increasing

Labor costs rise globally

Especially in China work force is limited, and employee loyalty is decreasing

Especially in China people are looking for office jobs, not workfloor jobs



How can we summarize?

Machine tool automation makes your machine tool more productive

Automation saves jobs

Technology is available and well proven

Automate today and be ready for tomorrows challenges

Automation from lot size 1 to 1.000.000 or more

Ease of use without specific robot knowledge using KUKA software packages


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