The Magazine for Cutting and Bending 2/17
Schindler: Rising to the heights of success
Tailored service solutions for worldwide known elevator company Driessen, Netherlands: How one company has transformed itself into an efficient operation with high added value Ultra Engineers, India: Ahead of the competition thanks to investment in a BySprint Fiber 6520 Focus Service: Innovative remote servicing solutions Innovation: The intelligent MES navigation system optimizes the process steps
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EDITORIAL
At a glance 4 Short News Events from the world of Bystronic 6 Schindler, Switzerland The Swiss elevator and escalator manufac turer presented the Bystronic service team with a challenge. The result was a strong customer relationship 12 Ultra Engineers, India The incredible story of the achiever Ashok Bhosale and his export-oriented business in Pune 20 Focus Service On-site from a distance – or what top service looks like today 25 Innovation MES software solution MES connects the manufacturing processes and creates transparency across the entire value chain 30 Driessen, Netherlands Solid craftsmanship and state-of-the-art machines have transformed the company
IMPRINT ystronicWorld – The Magazine for Cutting and Bending B Publisher: Bystronic, Corporate Communications Industriestrasse 21, CH-3362 Niederönz Overall responsibility: Jean-Pierre Neuhaus Editor-in-chief: Guy Hüsler Consulting, design, editing and production: Primafila AG, Zurich and Munich Circulation: 14,000 (German and English) Printed by: Köpflipartners AG, Neuenhof, Switzerland
Dear readers At Bystronic, servicing and customer service take top priority. With the expansion of its range of services, more efficient maintenance, and new digital solutions, Bystronic is focusing even more clearly on customer requirements. In the focus report on page 20, we present Bystronic’s comprehensive range of services and take a glimpse into a future with augmented reality. Our customers really appreciate this enhanced service orientation. Schindler, the well-known Swiss elevator and escalator manufacturer, chose B ystronic as its new main supplier for laser cutting and bending solutions not just thanks to the excellent quality of the machines, but because of the great customer support. In the cover story on page 6, you can read about how a new team is providing key customers with comprehensive support. However, many job shops, such as the Dutch company Driessen, also rely on long-term partnerships with B ystronic. In particular because they are dependent on fast and efficient series production solutions. On page 30, you can find out how Driessen was able to design its production environment in a flexible manner thanks to press brakes, fiber laser cutting systems, and automation systems from Bystronic. A sheet metal processing company in India was also able to enhance its laser cutting productivity and expand its range of cutting applications: Ultra Engineers is the first customer in India that has invested in a BySprint Fiber 6520. Read more about the benefits of laser cutting in the XXL format on page 12. The increasing complexity is changing the situation of many sheet metal processing companies. Orders come in with ever-shorter lead times. Hence Bystronic is developing a software solution that interlinks all the manufacturing steps and guides sheet metal products on the ideal path through the production process. On page 25 you can learn more about the navigation system for sheet metal processing.
Paper: PlanoJet FSC, M-real Biberist, 120 g/m2 Please contact Corporate Communications for all aspects of printing rights and all other queries: corcom@Bystronic.com Reprints not permitted without prior agreement.
Cover: Kitti Németh, Manufacturing Setup Team Leader with the Schindler Group, photographed by Daniel Moreno
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Thomas Huwyler Head of Global Key Account Management
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SHORT NEWS
Bystronic Tianjin wins safety production award In the spring of 2017, the Safety Committee at ystronic’s development and production locaB tion in Tianjin won a safety production award. The award was presented by the C hinese authorities in recognition of the exemplary fire prevention measures at the site.
Bystronic Tianjin’s Safety Committee is delighted with the award.
ByStar Fiber now with tube processing Insert tube, start laser, unload completed part. Laser cutting of tubes using the ByStar Fiber is now this simple. B ystronic offers a new rotary axis for tube processing with the high-end fiber laser.
The ByStar Fiber can be set up for a variety of tube profiles, round or rectangular, in just a few simple steps.
Long-life nozzles for a longer cutting life ystronic is developing new long-life nozzles for laser cutting. The B increased service life of the nozzles is achieved thanks to improved material characteristics. For users, this means cutting with outstanding quality for longer without changing the nozzle.
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High-quality material characteristics. The special alloy of the long-life nozzles increases their resilience against residue adhesion and wear.
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High functionality in a compact space ystronic’s new Xpert 80 press brake offers B anything but uniformity. It boasts increased power for versatile bent parts, increased bending length for complex individual parts and large series, as well as increased dynamics for fast cutting sequences.
Increased press capacity. Up to 80 tons bending force for a wide spectrum of applications.
Successful premiere for Bystronic in Japan Between July 12 and 15, 2017, more than 31,000 visitors attended the MF Tokyo, one of the largest and most important exhibitions for sheet metal processing worldwide.
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A premiere for B ystronic. Thanks to their ease of use, the Xpert 40 and the Xpert 150 in particular went down very well with the visitors to the exhibition.
The Bystronic Japan team at the MF Tokyo exhibition.
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SCHINDLER SWITZERLAND
Growing with the
global players
It is no coincidence that Bystronic has become Schindler’s main supplier in the area of laser cutting and bending. Within a very short time, Bystronic implemented individually customized solutions for the Swiss manufacturer of elevators and escalators – with a new team that is oriented specifically towards key accounts. Text: Guy Hüsler Photos: Daniel Moreno
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ave you recently been in a shopping mall, a train station, or a high-rise building? Then you most likely came into contact with a Schindler product. Every day, the family-owned company transports more than one billion people worldwide, it is represented by more than 1,000 offices in over 100 countries, and has production sites and research and development centers in the USA, Brazil, Europe, China and India. Schindler was founded in 1874 in the Swiss canton of Lucerne and develops passenger and freight elevators, escalators, and moving walkways. Whether in offices, hotels and leisure centers, or in other high-traffic areas, Schindler products can be found wherever there are crowds of people. And these crowds must at all times be transported safely, reliably, and using high-quality mobility solutions. Hence, the Swiss company also requires its suppliers, such as Bystronic, to adhere to its own high standards. But high standards mean more than just quality and delivery reliability. A code of conduct for suppliers, subcontractors, and service providers requires ethical standards, such as paying fair wages,
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Kitti NĂŠmeth, Manufacturing Setup Team Leader with the Schindler Group, is very satisfied with the ÂBystronic machinery that has been installed at the Schindler plant in Slovakia. BystronicWorld 2/2017
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“ Bystronic doesn’t simply sell machines, it offers comprehensive solutions and services.” Thomas Huwyler, Head of Global Key Account Management, Bystronic
and adhering to certain environmental standards in production. At the beginning of this year, Bystronic became Schindler’s main supplier for ystronic’s laser cutting and bending systems. For B Head of Global Key Account Management Thomas Huwyler, there are two main reasons for the new partnership with Schindler. “Bystronic doesn’t simply sell machines, it offers comprehensive solutions and services,” he explains. The second reason is the new and stronger focus on strategically important customers. Approximately three years ago, Bystronic expanded its global key account management in order to be able to provide large customers with even better support. Specialized employees are responsible for all the tasks relating to the key accounts. Bystronic’s aim behind this is to strengthen its relationships with existing customers. Since the end of 2015, Thomas Huwyler has complemented the global key account management worldwide with a team of three: Erik Metternich, who is responsible for customers in
Success thanks to global orientation and a clearly defined strategy The Schindler Group is a leading global supplier of elevators, escalators, and moving walkways. The company’s portfolio ranges from cost-effective solutions for small residential buildings right through to extremely demanding access and transport concepts for skyscrapers. Schindler’s aim is to achieve long-term growth that is stronger than the growth of the global market for elevators, and to secure the business with existing systems. This can only be achieved if the service network on the individual markets is continuously enhanced. Schindler’s success is based on the high level of motivation, the great commitment, and the expertise of its 58,271 employees. In 2016, 58 percent of Schindler’s staff worked in assembly and maintenance, 7 percent in production, and 35 percent in the fields of technology, sales, and administration.
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Europe and the Middle East, Jack Jia, who serves the needs of customers in China, and Jon Surch, who is responsible for key accounts in North and South America.
Top performance under time pressure When Bystronic’s Key Account Manager Thomas Huwyler’s phone rang, he was faced with a difficult task. After a thorough benchmarking process, comprehensive analyses of technological requirements, comparisons of the cost-effectiveness and customer service, Schindler had chosen Bystronic as its main supplier. For its production plant in the Slovakian town of Dunajská Streda, Schindler wanted three Xact Smart 225, an Xpert 250, and a 4-kilowatt BySprint Fiber 3015, with automation solutions. But this Schindler production plant is not just any industrial building. Covering an area of 36,000 square meters, the plant, which Schindler’s employees call “the green factory,” is vast. The production plant and logistics center supplies Schindler products for the European market and as one of the first industrial buildings in Europe, it was awarded the BREEAM rating “Excellent.” BREEAM stands for Building Research Establishment Environmental Assessment Method and is the oldest and most widely used certification system for sustainable construction. It was developed in Great Britain in 1990. Since it was established, more than 250,000 buildings have been certified. This process includes the evaluation of criteria in categories such as energy and water consumption, health and well-being, environmental pollution, traffic, materials, waste, ecology, and management processes. Buildings are certified “Pass,” “Good,” “Very Good,” “Excellent,” or “Outstanding.” The challenge for Bystronic was not only to meet the strict requirements of Schindler and the technical implementation. Kitti Németh, Manufacturing Setup Team Leader with the Schindler Group, read out a list of requirements: The equipment and tools must be defined, contracts drafted, the process workflow determined, safety guaranteed, lean processes and ergonomics established, the delivery sequence and deadlines adhered to, the staff selected, and the approvals obtained from the relevant authorities. All this within a period of five months. When Thomas Huwyler hung up the phone, he was aware that B ystronic usually required more time for the implementation of projects on this scale. “But I was able to rely on a good team,” Huwyler says. And five months later, all the machines are ready for operation. Németh says: “Three adjectives come to mind when I think of the collaboration with Bystronic: professional, punc tual, well-organized. This applies to the B ystronic teams both in Switzerland and in the Czech Re public.” Now, for several months, S chindler has been manufacturing elevator system components
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Thomas Huwyler manages key accounts, including Schindler. The elevator and escalator manufacturer benefits from Bystronic know-how on-site.
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Midyear, Bystronic installed a 4-kilowatt fiber laser cutting system at Schindler’s headquarters in Ebikon. The machine was ready for production in a short time.
using Bystronic machines at its factory in Slovakia. Németh sees clear competitive advantages: “The efficient fiber laser technology combined with software and automation solutions improves the competitiveness.” The new Bystronic solutions have been well received by the Schindler staff in Slovakia. Engineers, programmers, machine operators, and the maintenance team received training from B ystronic at an early stage. “Thanks to the hardware and software training, our specialists were able to rapidly start working with the new systems,” Németh explains. For Thomas Huwyler, it is a matter of course that the employees are involved in the decision-making processes at an early stage. “Simply installing a machine is not enough. If employees who are familiar with the operational processes are involved at an early stage, they will support the new solutions once they have been put into operation,” he says. And this is crucial. After all, these are the employees who are affected directly by the changes.
Swiss know-how for Asia A look at Schindler’s business figures shows that seven out of ten elevators worldwide are sold in Asia. However, a large part of the technological know-how for the elevators and escalators still comes from the company headquarters in the Swiss
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municipality of Ebikon. Approximately 1,500 of the worldwide total of more than 58,000 S chindler employees work there. In an interview with a Swiss daily newspaper, Schindler’s Chairman of the Board of Directors Silvio Napoli explained that the strengths of Ebikon lie in research and development, product knowledge, and marketing. “Many of the technological components and procedures, which, for example, flow into our elevator production in Asia, were developed in Ebikon,” he said. Midyear, Bystronic installed a 4-kilowatt fiber laser cutting system at Schindler’s headquarters. The machine is used to produce elevator components such as the cabin. “We primarily cut thin-gage material between 0.8 and 6 millimeters,” Frrok Prenka says. Schindler’s plant manager in Ebikon praises Bystronic’s service. “Service is also very important for our customers. Hence, we wanted a partner that offers good maintenance services,” Prenka says. By good service, he means fast response times. “We work in multiple shifts, our machines run around the clock,” he explains. In the event of complications, a B ystronic technician must be rapidly on-site. But communications also play an important role for the service quality. “Bystronic takes us seriously and provides support whenever we need it,” Prenka says. He gives the example of the commissioning of the 4-kilowatt fiber laser.
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“Within just two weeks the old machine was removed, the new system installed, test runs were performed, and the ramp-up initiated. The quality and performance are spot-on,” Prenka says. He sees potential with regard to the upstream and downstream cutting process. The fiber laser is so fast that the other production machines and systems must be brought up to the new speed. “But with Bystronic, we have the right partner to optimize our entire machine pool,” he says. Hence, Schindler did not select the next best supplier, but rather a partner with whom it is possible to work together over the long term. Key accounts are becoming increasingly important for Bystronic. In future, Thomas Huwyler intends to continue to develop and better establish global key account management at Bystronic. The internal structures, such as the maintenance services and development, must be matched even more precisely to the key account management processes. “Because we do not want to make promises to our customers that we cannot keep,” Huwyler says. After all, reliability and authenticity are the foundation of every long-term customer relationship. ■
Aiming high worldwide China The new headquarters of China’s largest daily newspaper, the People’s Daily, is located in Beijing’s thriving financial and embassy district Chaoyang. The office building is equipped with 22 Schindler systems. Switzerland The new headquarters of the biotech company F. Hoffmann-La Roche AG is one of Europe’s most energy-efficient high-rise office buildings. The Schindler systems that were installed there are equipped with an energy recuperation system that feeds excess energy back into the building’s electricity grid. Indonesia The Sinarmas MSIG Tower is located at the center of Jakarta’s Golden Triangle, the vibrant heart of Southeast Asia’s most populous metropolis. The skyscraper comprises 50 stories of offices and commercial space. In addition, its viewing platform offers fantastic views of the city. Poland The Warsaw Spire is not only Poland’s most prestigious building complex, but also one of its largest. The group of buildings consists of three parts, and offers office space, service areas, and retail areas. At its center, the 220-meter tower is the country’s tallest office building. Not only is the architecture futuristic, the Schindler elevators that are equipped with the latest myPORT technology are also pioneering. Mexico At 246 meters, the Torre Reforma is Mexico City’s tallest building. The skyscraper is equipped with state-of-the-art technology and was awarded the LEED “Platinum” certification – the highest level of certification for environmentally friendly, low-pollutant, low-emission, and sustainable buildings. Thirty-three Schindler systems, intelligently controlled by myPORT technology, contributed towards achieving this certification.
“ Bystronic takes us seriously and provides support whenever we need it.” Frrok Prenka, Plant Manager at Schindler’s Ebikon headquarters
Schindler’s plant manager in Ebikon, Frrok Prenka, praises the efficient cooperation with Bystronic.
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Sprinting
its way
to success
Ultra Engineers is the first customer in India to invest in a BySprint Fiber 6520, the new fiber cutting system that has brought about numerous efficiencies, giving it a competitive advantage especially in terms of large-scale components. Text: Swati Prasad  Photos: Arus Mayank
ULTRA ENGINEERS INDIA
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ome stories are just incredible. One such story is that of Ashok Bhosale, 51, the CEO of Ultra Engineers, a component manufacturer based in the city of Pune, about 150 kilometers from Mumbai in the state of Maharashtra. Coming from a middle-class background, Bhosale went against the grain by setting up Ultra Engineers at the young age of 25. All he had behind him were small personal savings and a few years of work experience. He had joined Tata Motors as a full-term apprentice after completing secondary school and had worked in the Indian automobile giant’s purchase department. When Bhosale set up his company in 1991, much of what he had learnt was on the job. The initial ten years were tough. But once Bhosale tasted success, there was no looking back. Today, Ultra Engineers manufactures high-quality metal components used in the oil and gas industry, the energy and power sector, as well as in automobile and heavy engineering projects. It exports 70 percent of its produce, manufactured at seven manufacturing units in Pune, to the United States. The remaining 30 percent is exported to Europe, or supplied domestically. Ultra Engineers serves
multinational customers like Alstom, GE Energy, JCB, Kirloskar, Larsen & Toubro, Bharat Forge, and Suzlon among many others. “From the beginning, I was very passionate about CNC (compressed numerical control) machines,” says Bhosale. Today, he has nearly 150 CNC machines, and among them is the state-of-t he-art BySprint 6520 fiber laser cutting system that can process sheet metal up to 8 by 2 meters. Along with this new machine, which was acquired in 2016, Ultra Engineers also has the Bystar L 4025 (120) with a Bylaser CO2 laser cutting system and a Bystronic press brake. Fiber lasers are significantly smaller than CO2 lasers and generate twice as much power from the same amount of current. A fiber cutting system is pri marily suited for processing thin to medium-thick sheet metal. It also cuts nonferrous metals like copper and brass.
Converting challenges into opportunity While working for Tata Motors, Bhosale realized that the supply chain in the Indian engineering industry was not fully developed. “The quality of
CEO Ashok Bhosale prides himself on fulfilling special customer requirements, and for that you need good communication between all parties.
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Ashok Bhosale, CEO of Ultra Engineers, sees a future for his firm in the aerospace industry, a branch with consistent growth and zero tolerance of mistakes.
the components was not good, and the supply chain was scattered. And everybody was playing the blame game,” he says. But Bhosale saw an opportunity hidden in this challenge. “I could do it all. I knew what the industry needed and had a good technical understanding,” he adds. He approached some companies and offered them end-to-end solutions for their metal components. “They were not convinced. But they gave me a chance,” says Bhosale. In time, Bhosale proved himself. “The shop floor teaches you what the education system can’t,” says Bhosale, He attributes what he has learnt to Tata Motors. “During my apprenticeship there, my intake was attending theoretical sessions in the morning and working on the shop floor in the afternoon,” he adds. Early on in his entrepreneurial journey, Bhosale realized that intelligence and hard work alone can’t get you world-class quality. “Technology and infrastructure are needed for catering to the global supply chain. Moreover, we need a long-term strategy for at least a decade or two to succeed in the business,” adds Bhosale. And that’s the reason why Ultra Engineers decided on state-of-the-art machines.
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“ The shop floor teaches you what the education system can’t.” Ashok Bhosale, CEO Ultra Engineers
“In the transportation and road-making equipment industry, 80 percent of the material to be cut is of 6 to 8 millimeters thickness. And this is where the BySprint Fiber 6520 comes in handy,” says Santosh Lokhande, Head of Operations at Ultra Engineers.
Improving productivity and margins When Ultra Engineers started out in 1991, competition was local. But today, the market is global in nature – and very dynamic. “The metal cutting and bending industry can be faced with peculiar demands. Some pieces are large, some small, while others may be thick or thin,” says Lokhande.
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ULTRA ENGINEERS INDIA
Ashok Bhosale, CEO of Ultra Engineers (left), and Santosh Lokhande (center), Head of Operations at Ultra Engineers, talking to Rohit Deo, Bystronic Area Sales Manager.
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Initially, the going for Ultra Engineers was tough. However, since 2000 Ultra Engineers has reduced its focus on automobiles and concentrated more on the energy sector. “The gas and steam turbine industries need very complex parts. Earlier, players used to import these, until we began making them domestically at far lower costs,” says Bhosale. This way, Ultra Engineers leveraged the cost arbitrage of manu facturing in India. The company then forayed into metal parts for renewable energy, beginning with wind turbines, and moving on to parts for the solar energy business over the last five years. “This is when we moved on to a high-growth trajectory,” says Bhosale. The biggest advantage for Ultra Engineers, according to Bhosale, was the fact that Bystronic was reliable. “Should problems arise, the crucial elements such as after-sales service, delivery of spare parts, and regular maintenance of the machines are only a phone call away,” he says.
On the BySprint Fiber 6520, Ultra Engineers works large sheet metal plates. The large-scale format also enhances the variety of cutting applications. Numerous small parts can be cut alongside large ones. This increases the system’s productivity, and wastage of raw material is reduced noticeably. All the planning for cutting metal plates is done using Bystronic’s software BySoft 7, which has a comprehensive range of functions, and is easy to operate. “Thanks to the BySprint Fiber 6520, there is a 5 to 10 percent drop in loss of raw material in the cutting process,” says Lokhande. In comparison to the CO2 laser cutting machine, this fiber laser system is much faster at cutting metal, has much lower running costs, and can be used for cutting nonferrous metal as well. “The basic strength of Bystronic is that the com pany has 22 engineers stationed in Pune. And, Bystronic has deputed two engineers and a onepoint contact for Ultra Engineers,” says Lokhande. According to Bhosale, Ultra Engineers was con-
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ULTRA ENGINEERS INDIA
Under the lead of CEO Ashok Bhosale (center) the company has achieved a strong position by offering end-Âto-end solutions. It can also meet special customer needs thanks to the extra large Xact 500M and work by hand. ÂBystronicWorld 2/2017
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ULTRA ENGINEERS INDIA
Stunning: the production hall of the Maharashtra Industrial Development Corporation, Ultra Engineers.
vinced about both cost and quality insofar as the fiber laser system was concerned. “The faith built by the CO2 laser cutting machine and the press brake (both were bought in 2015) was quite high,” adds Lokhande. Moreover, due to lower wastage brought about by the BySprint Fiber 6520, along with the lower cost of operations, the company’s margins have improved, says Lokhande.
Working towards perfection It’s not easy doing business in India. According to Bhosale, businesses like his face considerable challenges. For instance, the cost of raw materials has been on the rise. Moreover, “getting the right quality and on-time delivery of raw materials as well as finished goods continues to be a challenge,” says Bhosale. And then, convincing banks to pro-
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vide finance is also a difficult task, especially for small- and medium-scale enterprises. “India lags behind in quality. Many people can make okay quality. But international quality and on-time delivery are a challenge. Raw material is a constraint both in terms of cost and quality,” adds Bhosale. For this reason, a system like the BySprint Fiber helps – as it improves the margins, thereby increasing the profitability of the company. “It works around the clock, without giving any trouble,” adds Lokhande. In order to grow his business and be in closer contact with the customers, Bhosale is keen on implementing an enterprise resource planning (ERP) system from SAP. “Diversification has helped us bring sustainability into our business,” says Bhosale. And now, he wants
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ULTRA ENGINEERS INDIA
to get into manufacturing components for the aerospace industry. “Aerospace is the only business that promises consistent growth in the future. In other businesses, there is no guarantee of future orders,” he says. However, the aerospace industry is complex. What Bhosale likes most about the industry is its culture of zero deviation. “You cannot afford to make mistakes,” he says. Surely, with such ambitious plans, Ultra Engineers is poised to scale new heights. ■
Swati Prasad is an independent business journalist based in Delhi. She reports from India for several publications overseas and has worked as a correspondent and editor for The Economic Times, Business Standard, The Indian Express, and Business Today.
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Ashok Bhosale, CEO of Ultra Engineers (left), talking to Rohit Deo, Bystronic Area Sales Manager.
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FOCUS SERVICE
Experienced ÂBystronic workers pass on their know-how so customers can start producing once the machine is installed.
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FOCUS SERVICE
How
top service works
Companies can always rely on solutions from B ystronic. Regular servicing ensures smooth production processes and makes costs more predictable. At the same time, Bystronic is driving forward digitalization and developing innovative solutions that use remote maintenance to prevent machine downtime. Text: Guy Hüsler Photos: Manuel Stettler
“I
t is the same as taking the car in for a service,” explains Dominik Hanisch, Product Manager Spares, Consumables, and Tools at Bystronic. After a certain number of miles, the car is checked thoroughly, the oil topped up, and the wearing parts are replaced if necessary. As a result, the owner of the car can enjoy the peace of mind that comes from navigating the roads safely and comfortably. The situation is similar for Bystronic customers. After a service has been carried out, the customers can be certain that they will be able to produce efficiently and at the highest level of quality. “With increasing laser output and automation levels, process reliability is growing in importance,” Hanisch explains. Particularly for customers who have replaced several laser cutting machines with a single Bystronic fiber laser system.
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FOCUS SERVICE
“ Fast service is absolutely vital, because otherwise the whole production comes to a standstill.” Dominik Hanisch, Product Manager Spares, Consumables & Tools
“Our customers used to require several conventional machines to produce what they can now achieve with just one fiber laser,” he says. Hence, many B ystronic machines operate virtually around the clock. And if the machine is connected to an automation solution, the customer must be able to rely fully on Bystronic. Upstream and downstream production steps are dependent on each other and interconnected. “So, if a system breaks down, fast service is absolutely vital, because otherwise the whole production comes to a standstill.”
Smooth production ystronic offers a comprehensive range of services. B Advice and support with new installations or the replacement of existing machines relieve the
burden on customers. Regular service and maintenance, a helpline, and rapid assistance via remote service are available at all times. Updates and upgrades as well as instruction and training for customers’ operators and staff complement these service offerings. “We attach great importance to the service quality,” Hanisch emphasizes. Good quality means not only the technical performance on-site, but also consulting and support throughout the entire life cycle of a Bystronic solution. In order to prevent any damage and cost-intensive repairs, systematic ystronic systems by a and regular inspections of B service technician are advisable. If problems nevertheless occur, well-trained experts provide the customer with immediate support via the helpline. Thanks to its decentralized service organization, Bystronic has a dense and effective service network in every country. Customers and service technicians can rapidly access the spare parts they require at any time. “If a customer requires a spare part, it should be delivered the next day at the latest,” Hanisch says.
Original wearing parts As a product manager, Dominik Hanisch continuously works on enhancing B ystronic’s range of services. Because service excellence is the top priority, the requirements of logistics, product development, and, above all, of the customers flow directly into developing service further. Take the new longlife nozzles. The improved material characteristics increase their service life. For users, this means cutting with outstanding quality for longer without changing the nozzle. Another example are the new nozzle adaptors. “Previously, both the n ozzle and the adaptor used to break when the cutting head collided with a sheet metal part that had tilted,” Hanisch explains. “Now the nozzle adaptors have a sleeve with a predetermined breaking point.” This means that now only the sleeve has to be replaced. The adaptor itself usually remains intact. “This considerably reduces costs for our customers.” Good service and maintenance also means designing wearing parts to have the longest possible service life and to be able to identify when they will need replacing. “These innovations ensure that the customer has reliable production
With augmented reality technical modifications do not require a great deal of prior knowledge.
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Although digital contact channels are gaining importance, on-site service remains key.
processes,” Hanisch says. Developments such as the long-life nozzle have endurance tests with 50,000 cutting hours behind them and were thoroughly tested by customers before they were launched on the market. In future, Bystronic intends to increasingly put wearing parts from suppliers through various endurance tests. A new label along the lines of “Certified and approved by Bystronic” will allow customers to see which spare and wearing parts are particularly well suited for Bystronic machines.
In person on-site Technical problems can usually be solved by Bystronic technicians over the phone or using remote maintenance solutions. Although digital contact channels, such as live chats, are clearly gaining importance, on-site service, the personal conversation between the customer and the service technician, remains key. Approximately one quarter of B ystronic’s employees work in service:
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Around the clock, 600 employees serve the needs of customers around the globe and B ystronic will continue to expand this service in the future. Unexpected outages are reduced through the rapid availability of spare parts, personal service on-site, and remote service. Additional services that are increasingly in demand include coaching in user skills as well as advice and instructions on all aspects of machine operation. “In future, we increasingly want to offer training for our customers’ machine operators at our training centers,” Hanisch explains. The aim is to enable customers who purchase a new B ystronic machine to start using it efficiently as quickly as possible. “If our experienced workers pass on their know-how, the customers can immediately start producing once the machine has been installed. However, Bystronic’s ByAcademy training center will also enable existing customers to benefit from regular advanced training courses. Always producing optimally requires continuous advancement and
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FOCUS SERVICE
staff support.” Hence Bystronic is expanding its range of comprehensive and specialized advanced training.
Digital services The possibilities of digitally assisted maintenance services are increasing: Many service technicians are already using tablet computers. The ByExcellence software enables technicians to rapidly gain an overview. They can see what machines the customer has, what problems were reported, and the history of the past weeks and months. They can keep track of when and why the customer called the hotline. This enables the service technicians to thoroughly prepare for their service call and further increases the efficiency of the on-site service.
“ It is possible to compare the productivity of machines in order to carry out targeted optimization measures.” Daniela Schwarz, Product Manager for Digital Services
Dominik Hanisch and Daniela Schwarz are developing a new range of B ystronic services. The requirements of logistics, product development and, above all, of the customers flow directly into developing service further.
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The machine data is key to digital solutions. Using components that are able to communicate enables Bystronic to analyze a wide range of complex data and thus to generate a tangible added value for the users. “Naturally, only with the customers’ consent,” Daniela Schwarz, Product Manager for Digital Services, emphasizes. Starting in 2018, selected fiber laser cutting systems and bending machines will be equipped with so-called connectivity kits. “Bystronic will use the collected data to offer a variety of maintenance services, which will increase the efficiency and process quality of the customers’ production processes,” Schwarz explains. With ByCockpit, it is already possible to visualize the efficiency within the sheet metal processing environment in real time. However, transparency regarding machine performance, manufacturing efficiency, and the raw materials warehouse is only a small part of the range of digital services. “The data resources will allow us increasingly to offer our customers ’predictive maintenance’ solutions. For example, the flow rate, temperature, or laser output can be measured in order to check whether all the components are working optimally. If there are any deviations, B ystronic informs the customer and coordinates the further course of action. The continuous monitoring of the machine’s condition using all the available data and rules also enables tangible competitive advantages to be generated for the customer. “It is possible to compare the productivity of machines in order to carry out targeted optimization measures,” Schwarz explains. The augmented reality concept shows how Bystronic will intelligently link digital services with data and know-how in the future. Special glasses allow the user to see superimposed information about how the machines should be adjusted. “This allows customers to carry out technical modifications themselves without requiring a great deal of previous knowledge,” Schwarz explains. The operator is guided through the process step by step, and because both hands are free, they can immediately carry out any modifications that are required. Augmented reality is opening up many opportunities for Bystronic to develop new enhancements and added value. In addition to remote maintenance, Daniela Schwarz also envisages using the data glasses for e-learning applications. “Our technicians have a great deal of know-how, which we want to enable our customers to tap into using augmented reality,” she says. ■
www.Bystronic.com/ services-and-support
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Digital networking of all the process steps: With the B ystronic MES, users plan, monitor, and control their production from the incoming order right through to the completed product.
The
navigation system for sheet metal processing ystronic and Lantek are developing an MES software solution B for sheet metal parts production. The B ystronic MES interlinks all the manufacturing steps and guides sheet metal products on the ideal path through the production process, much like an intelligent navigation system. Text: Oliver Hergt Illustrations: Armin Schieb / Sepia
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INNOVATION MES SOFTWARE
N
owadays, people who want to reach their destination in the shortest possible time rely on a satellite navigation system. The software knows the shortest route. It tells the driver precisely when they will arrive at the defined destination. A satnav system is a valuable assistant when navigating complex and sometimes confusing traffic conditions. It maintains an overview, avoids detours, and immediately responds to changing conditions, such as short-term traffic congestion. What if there were also such a satnav system for sheet metal processing companies? An intelligent software that helps manufacture and ship products with precisely defined costs and deadlines. An assistant that creates transparency and describes the ideal path, in order to guide sheet metal products through increasingly complex manufacturing environments. Nowadays, for sheet metal processing companies that want to produce on time and in a cost-optimized manner, all these considerations lead to a manufacturing execution system (MES). Such a planning system
helps them to digitally record all the available resources within their production environment and ystronic MES, to make ideal use of them. With the B Bystronic is realizing the vision of a software suite that can do just this: a manufacturing execution system, which B ystronic is developing in collaboration with the Spanish software supplier Lantek. What makes the B ystronic MES so special is its consistent orientation towards sheet metal processing. With this system, Bystronic and Lantek are combining their expertise for machine tools and software design. The result will be an MES software solution that will allow users to record, plan, and evaluate every individual manufacturing step of their sheet metal products.
The path through complex p roduction Increasing complexity is changing the situation of many sheet metal processing companies. Orders come in with ever-shorter lead times. The manufacturing steps for the parts to be produced are
INNOVATION MES SOFTWARE
becoming more elaborate. At the same time, the requirement to minimize costs and delivery times is increasing. Under these conditions, it must be possible to manufacture small series right down to a batch size of one just as profitably as large series. What is more, it is becoming increasingly impor tant to orient all of the business areas towards fluctuating manufacturing situations. Order management, procurement, production, logistics, shipping, and controlling must be linked to the flow of information in the background behind the production processes. The Bystronic MES creates digital transparency across the entire added-value chain of sheet metal products. All the steps from the incoming order right through to the shipping of the completed product are digitally recorded. This not only enables products to be manufactured according to defined costs and deadlines. The capabilities of the Bystronic MES go even further. It is the brain for the entire production process. It never forgets an order in spite of the hectic activity of day-to-day
business. It is forward-thinking. The Bystronic MES maintains an overview of all the open production parts in the order pool. On the shop floor, it allocates the created cutting and bending plans to the resources of the available machines. Mixups of production parts with allocated cutting or bending plans are virtually ruled out. This prevents rejects. The MES also allows bottlenecks at manufacturing stations and long idle times to be avoided. In future, thanks to the Bystronic MES, procurement and logistics will provide the required materials depending on the order situation and supply them “just in time.” This means that the materials arrive at the manufacturing stations in precisely the right quantity and exactly when required for the current jobs. This makes the manufacturing processes leaner. Throughput times and tied-up capital are reduced and streamlined to achieve maximum efficiency in the face of fluctuating order situations. Ultimately, the end customers will also benefit from the transparency and reliability of the B ystronic
The B ystronic MES helps users to perfectly attune the process steps, integrated machine systems, and workstations within their manufacturing environment. This enables throughput times and costs to be optimized.
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In complex manufacturing situations, the Bystronic MES increases the flexibility and versatility of the production processes. Much like a navigation system, it supports users and helps them to quickly respond to their customers’ changing requirements.
MES. They can always obtain precise information about the current stage in the manufacturing of their products and when they will be delivered. After completion of the order, the manufacturing data is available for evaluation. The Bystronic MES will enable the controlling department to precisely calculate whether the actual and the target values relating to costs, times, and material are within the defined limits, and what rejects and idle times accrued at the individual manufacturing stations. All this information is what makes it possible to perform in-depth evaluations of the entire process chain and subsequently achieve sustainable optimizations.
Modular start and gradual growth The Bystronic MES has a modular design. The entry level comprises an extensive basic package that includes the most important functions that allow the MES system to be integrated into the user’s infrastructure. Initial upgrade modules will expand the functionality of the basic version according to the customer’s requirements. Bystronic and Lantek are already developing additional solutions. This will enable users to build their
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customized Bystronic MES that is tailored precisely to their manufacturing environment. Once the basic version of the Bystronic MES has been implemented, users can digitally integrate additional manufacturing stations on a step-by-step basis. This enables the B ystronic MES to grow with the user’s manufacturing environment. The basic version of the MES, which B ystronic offers since summer 2017, initially enables the interactive integration of the laser cutting process step. The bending process step will follow next. B ystronic will thus enable an open data transfer with the BySoft 7 programming software and networking with Bystronic’s own laser cutting systems. For instance, the end-to-end integration facilitates feedback about the manufacturing status of the machines. The integrated B ystronic cutting systems provide fully automatic status messages about the start of cutting jobs, the remaining processing time, and the completion of jobs. This information flows via the Bystronic MES back to the user’s ERP system. In the same way, the cutting plans from BySoft 7 are transmitted directly to the MES and from there they are distributed to the integrated Bystronic laser cutting systems. Conversely, production parts
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INNOVATION MES SOFTWARE
Digitalization of B ystronic’s own production Bystronic is driving forward the digital integration of
resources that can be used in an optimal manner to
the sheet metal parts production at its own business
prevent bottlenecks. The B ystronic MES creates trans-
location. The Bystronic MES is already being used suc-
parency about all the integrated production areas.
ystronic’s Swiss headquarters in Niederönz. cessfully at B
Furrer emphasizes that optimizing the costs and
Fabian Furrer who is responsible for production in
throughput times is a key factor for the global com
Niederönz explains: “The B ystronic MES makes our
petitive success of the Swiss production location.
sheet metal processing more transparent and leaner than was ever possible before.” At Bystronic, the MES is connected to two fiber lasers, a CO2 laser, and a manual welding workplace. The laser cutting machines are integrated interactively. They transmit all the information from the manufacturing stations to the MES in a fully automatic process. From there, the data is sent directly to the business location’s ERP system. The cutting plans for the laser cutting systems are created using BySoft 7. The programming software is also interactively connected to the Bystronic MES. “We are gradually expanding the B ystronic MES, in order to avoid lengthy production downtimes,” Furrer explains. After laser cutting and welding, the next step will be to integrate an automated bending station, several manual bending machines, and two welding robots into the B ystronic MES. Later on, the machining processing center will be added.
Fabian Furrer, Head of Production in Niederönz.
The B ystronic MES is already proving its worth in Bystronic’s production, says Furrer. It has already been possible to reduce the paperwork and long walking distances in the integrated areas. Thanks to the fully automatic feedback from the laser cutting systems, the documents that were previously used to record manu facturing data and then manually enter it into the ERP system have been eliminated. Moreover, the operators at the workstations now receive all the important information from production planning in digital form on their screens. This makes the manufacturing plans, processing instructions, and deadlines available simply by tapping on the touch screen of any connected
“ The Bystronic MES makes our sheet metal processing more transparent and leaner than was ever possible before.” Fabian Furrer, Head of Production in Niederönz
workstation. “In future, this will make it easier to analyze and improve our manufacturing processes,” Furrer explains. It has already been possible to identify free
that already exist in virtual form as a cutting job in the Bystronic MES can be adapted in BySoft 7 at any time. From there, the updated data flows back to the Bystronic MES and then on to the allocated laser cutting system. In addition to the interactive integration of the laser cutting process, the Bystronic MES also ties in
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manufacturing stations with third-party systems and manual workstations. These manufacturing stations return simple status messages about the beginning and completion of the processing steps to the Bystronic MES. ■
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DRIESSEN NETHERLANDS
Successfully adapting to a rapidly
changing world
DRIESSEN NETHERLANDS
Located in the so-called Brainport Eindhoven area, the southeastern Netherlands’ leading technology region, the sheet metal part company Driessen keeps up with today’s societal challenges by choosing adaptability. With the next generation taking control, they have ensured a successful transition from a declining traditional manufacturer into a high value-added supplier in a very short time. Text: Erika Claessens Photos: Erik van der Burgt
T
he sheet metal part company Driessen Las- en Plaatwerk B.V. is situated in one of Europe’s leading technology regions, a stone’s throw from Eindhoven and home to many renowned knowledge-intensive companies. The Dutch firm manufactures sheet metal parts and assembles them to the highest quality standards. When selecting a second-tier supplier such as Driessen, the demanding customers require expertise in the precise, rapid, and efficient processing of serial repeat orders covering everything from individual parts to volume production. To meet these demands Driessen is equipped with a hypermodern range of machinery and can boast of solid craftsmanship. For the last eight years the company has also collaborated with its subsidiaries Kempmetal and TeamWorks for the turning and molding of metal parts. Their synergistic corporate activities complement each other, especially when it comes to providing all-in solutions and manufacturing complete mechanical (sub)components. I meet Stefan Driessen, 35, on a rainy day in June in the rural village of Eersel where the company is situated. He is a former attorney-in-law with years of experience in urban planning, but now takes care of the Driessen sales department. At the end of 2009, Stefan and his brother Dennis, 36, took over the company from their father, together with the former General Manager of Kempmetal, Olaf Janssen, 48. With his years of experience in the metal sheet industry Olaf is the company’s Technical Manager, while Dennis, a former project
Hans van de Meerakker (right), Head of Bystronic Benelux BV, knows the needs of his customers. He and Driessen Las- en Plaatwerk B.V. co-owner Stefan Driessen are happy with the company’s successful turnaround.
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DRIESSEN NETHERLANDS
manager in urban planning, is in charge of Finance, HR, and Project Management. Their totally different backgrounds make the team very complementary. I want to find out how the new young-blooded directors can meet the demanding needs and high standards of the knowledge-based Eindhoven industries in this competitive era.
Old school Stefan takes me on a guided tour through the factory and proudly shows me the company’s brand-new equipment: two precise Xpert bending machines and a ByStar Fiber 6000 laser cutting system, equipped with an automatic loading and unloading system. “We didn’t invest in brand-new machines from one day to the next,” he says. “My father, Ger Driessen, who founded the company in 1979 and retired after 37 years at the helm, was a die-hard believer in the old-school methodology.
“ A good level of understanding of the client’s requirements helps save time and facilitates the coordination of the tasks.” Stefan Driessen, Co-owner, Head of Sales and Marketing
He had a wide range of knowledge and expertise, and in the 1980s helped the company become more successful than ever. Getting things done was his slogan. My father could make accurate calculations for precise metal sheet orders from memory. It was hard to believe that a computer could do better than him. But the more automation was fostered and the more things got digitalized, the more we realized we needed to change.”
Communication and adaptability Stefan continues: “When my brother Dennis and I took over the company together with Olaf, we knew that just being smart and taking firm decisions as my father had, was no longer enough for a sustainable business strategy. As a second-tier supplier we realized that the only way forward, to outperform our competitors, was to improve the machinery and communicate more effectively with the client. A good level of understanding of the client’s requirements helps save time and facilitates the coordination of the tasks during the manufacturing process. Because in today’s rapidly changing world, excellent communication skills and adaptability are required more than ever. We regularly talk with our clients about the different aspects of the manufacturing process, like budget or time allocation, and brainstorm to find solutions. Our aim is to ensure our clients are satisfied with the end results and every project is deemed
Every part is made with the same high level of precision.
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DRIESSEN NETHERLANDS
Customers require precise, constant bending results and these are easy to achieve with the Xpert press brake.
successful. That means adapting to the different needs of our customers, so we might have to create prototypes for metal pieces when their product requirements do not fit the standards.”
The 3D breakthrough The young director walks with me to one of the production rooms and introduces me to two employees in their sixties. These two workers illustrate perfectly one of the major challenges manufacturing faces with increasing automation and digitalization. “When they retire, there will be no
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one to succeed them, because the younger generation is not trained in the same ways as the older generation. With the breakthrough of 3D computerization in the metal forming industry, younger employees simply lack the skills and the competence of old-school techniques,” Stefan states firmly. “Nevertheless, our clients are leading firms in the world of chip-making equipment and component technology and they require fast, proven services and high-quality precision. Therefore, we had to update our machinery. Our first priority was to renew the bending machines. We owned six press
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DRIESSEN NETHERLANDS
Almost like playing Tetris. The 3D model is scanned in the office and the machines are programmed offline.
“ Since the installation of the new software for the ByStar fiber laser cutter, our productivity has increased significantly.” Stefan Driessen
DRIESSEN NETHERLANDS
brakes in total, so we started by replacing two of them. The choice of the ByStar Fiber 6000 laser cutting system was determined by the purchase of the press brakes. The remaining four presses, as well as another laser cutter, will be renewed in the next five to six years.”
opportunities. Investing in new high-quality machines and improving the communication with their clients was key to countering the defeats. The transition of a traditional company into a highvalue-adding supplier has proven to be a successful one. ■
The press brake rules As he stands in front of the extra high Xpert 200 he shows me the technological benefits and explains: “The Xpert is a press brake with a very high position and repetition accuracy because it doesn’t produce angle errors. It offers first-class bending results with a fully automatic and dynamic crowning system that uses pressure sensors and corrects in real time. We therefore achieve precise, constant bending results. It’s obvious we cannot afford to lose clients due to slight deviations of a bending angle. Accuracy is key for the products we offer. The 3D BySoft 7 Bending CAM software is comprehensive and easy to handle even by younger employees. The 3D model is scanned in our office and the machines are fully programmed offline. This saves a lot of time at the machine and gives a perfect up-front feasibility check. With the six-axis back-gauge Xpert we are often surprised when we need to bend. The machine is already set and ready to go.”
Erika Claessens works as an independent journalist out of Antwerp, Belgium, with her principal topics being entrepreneurial innovation and technology.
About Brainport Brainport is one of Europe’s leading technology regions. Located in the southeastern Netherlands near Eindhoven, it is known worldwide as a center for innovation. Brainport plays an important role in the Dutch economy and is key to the Netherlands’ competitiveness abroad. Many of the technologies used in smartphones, houses and cars (such as chips) were developed here. Among the companies that are part of Brainport are spin-offs from Philips, such as ASML, NXP, Sapiens SBS (Medtronic), and Silicon Hyve, and manu facturers like FEI, DAF, and VDL. Many Eindhoven University of Technology (TU/e) start-ups have converted their ideas into highly successful companies. Disruptive start-ups also benefit from the enormous wealth of experience and the unique competencies of large corporations nearby.
As simple as Tetris Stefan has now evolved into a professional tour guide and entices me to the ByStar Fiber laser cutting system: “Right now we are forming the metal casings of 78 parking lot pay terminals. At the end of the process we deliver an entirely assembled product that meets the client’s high-end requirements.” I notice a monitor screen that resembles the colorful Tetris game, and Stefan tells me that the software program is a huge advantage because of its simplicity. While pointing at the graphics, he explains that the software of the ByStar Fiber laser cutter is as easy as the game, while still offering a comprehensive range of functions. “This way we maintain an overview while completing the metal planning and cutting quickly, affordably, and reliably,” Stefan says. “Since its installation our productivity has increased significantly, and our turnover in 2017 is up by 20 percent compared to the same period in 2016,” he concludes. Leaving the picturesque Eersel, I understand that Driessen could only handle the challenges of the future by adapting to the rapidly changing world. Rather than regarding automation as a threat, the management team has chosen to focus on the
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Founded by Ger Driessen in 1979, Driessen Las- en Plaatwerk B.V. has automated the production of sheet metal parts.
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The nächste Der next stepSchritt towards in die digitale digital manufacturing Fertigung Digital Alle Prozessschritte networking for der allBlechfertigung production steps digital of sheet vernetzt. metal processing. Planen, überwachen Plan, monitor,und andsteuern control your Sie Ihre production Produktion from vom theAuftragseingang incoming order bis hin right through zum fertigen to the Produkt. finished product. Mit dem With Bystronic the Bystronic MES entwickeln MES, you Sie die höchste achieve the highest Produktivität, possible level dieofIhre productivity Fertigungfor erreichen your production. kann.
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