Factory Automation Systems.

Transcription

1 Factory Automation Systems.

2 SMOOTHER PRODUCTION FLOW MEANS GREATER PROFIT Automation benefits Here s how Fastems puts you in control The key to manufacturing productivity and profit is keeping your process running smoothly. Doing so requires a continuous stream of reliable information so you can control and optimize material flow. Fastems has the software, automation tools and global support to do just that. Proven in thousands of installations around the world, Fastems systems help reduce lead times, assure product quality and enable reliable deliveries. All of which adds up to satisfied customers. Fastems Manufacturing Management Software enables you to focus on key performance targets and to easily modify them as necessary. Fastems solutions give you total control of your production. You may quickly and easily respond to changes in customer demands, plan for future expansion, accurately schedule production, and utilize capacity more efficiently. A worldwide presence Become competitive Vastly improve cycle times and throughput, reduce costs per part, efficiently adapt to changes, increase utilization rates. Simply: become more competitive! Easy to use Fastems control system is a collaboration tool for everyone involved in production. Both our software and equipment are designed with work environment, safety and ergonomics in mind. Safe investment 30 years of experience. Thousands of delivered systems. We can find the optimal production solution to suit the needs of any machine shop. Be in control Managing production is now easier than ever. Our software puts you in control of your production resources, orders, NC programs, tool presetting and more. A privately held company founded in 1901 with world headquarters in Finland, Fastems operates in nine European countries, the United States, Japan and China, with manufacturing facilities in Finland and Germany. Fastems has 380 employees and 90 million euro turnover. QUICK FACTS /7 7,200 First system installed and still in use! Technical support worldwide Fastems record: spindle hours per year 4, Installed systems worldwide Annual turnover (million euros) Employees worldwide

3 MANUFACTURING MANAGEMENT SOFTWARE MMS MMS is an open, machine tool independent software that does not require separate software for NC program, tool, material or production order management. The MMS production suite is a completely modular software solution, giving you the freedom to choose just the functionalities you need. Additionally, it s easy to upgrade your system if your needs change over time, for example when adding manual production cells. Usability MMS provides just the right set of tools for each user. This straightforward shopfloor interface enables operators to concentrate on what s hot at the moment. NC program, tool and fixture management You can predict and prevent unnecessary stops and slowdowns with centralized tool and NC program management, while optimizing fixture usage. Logistics management Integrated logistics management frees operators from repetitive tasks. It also lets you manage job lists and billets for manual production on lathes and other machines. Integration Fastems MMS is ready for your ERP, MES, TDM, FANUC, Siemens, Heidenhain and much more. Simulation Proactive pallet scheduling frees your operators from juggling too many resources, thus optimizing your manufacturing process. Real time visibility Whether you wish to track KPIs, investigate the effect of an urgent production order, or view a complete production scenario, you ll have what you need in just a matter of seconds. MMS-2000 Material Pallet Management MMS-2300 Manual Cells MMS-2100 Automatic Material Delivery FASTEMS MMS CORE Program and tool data libraries, production order management, fine scheduling, diagnostics and reporting, master data management, production scheduling, and standard device interface. MMS-3010 ERP Interface MMS-4220 Tool Identification (ID-Code)* MMS-4100 NC Program Transfer and Tool Checking* MMS-4200 Tool Data Transfer to Machine Tool* MMS-4210 Tool Presetting Station Interface* MMS-4240 TDM System Interface* MMS-4230 Operation Panel for Machine Tool Magazine* MMS-4010 CAD/CAM Interface * MMS-5100 Remote Monitor MMS-5000 Status Monitor MMS-6000 Dashboard MMS-7200 Machine Tending MMS-7100 Auto Loading MMS-7000 Deburring MMS-4300 Central Tool Store* * Available only for Fastems-certified machine tool interfaces.

4 MMS Dashboard for production managers MMS Station Commander for shop floor operators Online monitoring Performance visualization Key production figures User configurable widgets Intuitive touch screen interface Instructions on which parts to load and when Advanced error recovery MMS Data Manager for production planners All user interfaces are browser-based Master data management: production orders, parts, and fixtures Production schedule management Production logs All user interfaces are browser-based which provides the freedom to use them anywhere with laptops or tablets.

5 ROBOT CONTROL SOFTWARE The FASTWIZARD was originally developed to be a basic user interface for robot cells. One of the key drivers was to enable the use of robot cells without dedicated robot specialists. Over the years it evolved into a software platform solution with a wide array of value adding functions for easy control of the manufacturing process and the resources within. FASTWIZARD benefits Easy day-to-day operation without dedicated robot experts This makes it easy to use your manufacturing equipment. All machine operators can run production. Wide array of value adding options available Software is configured based on the needs of your manufacturing solution. The right value adding options complete your automated manufacturing process, providing optimum efficiency and quick return on investment. Visual user interface The state of your production equipment can be seen at a glance for effective system operation. Eases your production planning Control software has many options to simplify production management. Choose manufacturing orders, resource checks and simulation functions to see how long your equipment is set up to run. This also allows you to see what changes must take place and at what time for the system to keep running. Visual User Interface: Online display for production equipment. Order Management option. Easy management of production orders. Resource availability info for orders. ROBOT CONTROL SOFTWARE FEATURES Tool management for deburring application. Tool simulation. OFFLINE ROBOT PROGRAMMING FASTSIMU MODULE-110 Single Part Routing MODULE-120 Production Order Management MODULE-200 Statistics MODULE-300 Material station management MODULE-400 Measuring Machine Interface MODULE-500 Deburring Tool Management MODULE-600 Parametric Part MODULE-700 Sampling MODULE-3010 ERP Interface MODULE-4100 NC Program Transfer and Tool Checking MODULE-5100 Remote Monitor Fastems offering includes one of the most powerful software programs for offline programming and simulation. FASTSIMU is a dedicated software application for robotic milling, grinding, and deburring tasks. It includes extended in-house developed features to handle the massive number of positions needed. This is especially true for finishing complex geometry and 3D-curved surfaces, and it supports a wide range of native CAD formats. Fastems robot cells fully support offline programming. This is assured through superior mechanical accuracy and a deep understanding of offline programming methods. MODULE-121 Parallel Part Routing MODULE-310 Palletizing Wizard MODULE-4200 Tool Data Transfer to Machine Tool MODULE-4010 CAD/CAM Interface Program complex features off-line and save valuable production time.

6 FASTEMS 8760 SERVICE With more than 4,000 systems delivered to over 40 countries, Fastems makes customer support a priority. That s why we have service hubs in Europe, Asia and the US for quick response to your facilities anywhere in the world. Global response, less downtime Fine-tune for greater profit The 24/7 technical support team is at your service to make every one of the 8760 hours in each year as productive as possible. Our track record shows that in over 85% of cases we're able to recover the system in operation remotely, on average, in less than three hours. We're happy to help you improve your system with diagnostic reports that enable you to quickly identify bottlenecks and fine-tune your system for greater profitability. Lifetime software About 80% of all systems will be modernized or extended during their lifetimes. Fastems has everything you need for minor upgrades or major extensions to continue the life and efficiency of your FMS. Fastems software and control architecture is easily upgradable and engineered to last the life of your system when properly maintained. We provide access to control software updates, patches, error corrections and enhancements to keep your process running smoothly. Right spares, quick delivery Genuine factory spare parts are readily available in Fastems hubs located in Europe and the US for quick shipment to your facilities anywhere in the world. GLOBAL SERVICE 4000 SYSTEMS Service in Europe, Asia and US supporting you globally. About 4,000 systems worldwide are served by our life cycle service organization. 85% SUCCESS RATE FOR REMOTE CASE SOLVING Our technical support team can solve more than 85% of service requests remotely. 80% MODERNIZED Be ready when production needs change Backup ensures quick recovery Regularly backed up system data is critical in case the unexpected happens. Good backups could save weeks when resuming production. About 80% of all systems will be modernized or extended during their lifetime.

7 FMS ONE FMS ONE is a configurable flexible manufacturing system that enables the use of a variety of machine tool sizes and pallet setup station types, while providing versatile material management. FMS ONE enhances your productivity with several key features. The scheduling and resource calculation based system, for example, offers great benefits in tool management and overall productivity. Visualization capabilities help users and management easily control changing situations. Technical information SYSTEM TYPE ONE- LD-700 ONE- LD-1000 ONE-MDR-750 ONE-MDR-1100 ONE-MDR-1800 ONE-MD-1500 ONE-XMD-2500 ONE-XMD-3000 ONE-SCR-2000 Load weight incl. pallet (kg) 700 1, ,100 1,800 1,500 2,500 3,000 2,000 Nominal pallet size (mm) x ,000 x 1, x 630 Maximum load size (X x Z x H mm) Load rotational diameter ( Ø mm) , x 800 x 1, , ,250 1,125 1,125 1,800 1,000 1,000 1,250 1,600 1,400 1,400 1,800 x 1,800 x 1, ,000 1,250 1,100 1,600 1,800 Material management Yes Yes Yes Material pallet size 800 1, , x 1,200 Custom Machining pallet storage 2 4 levels 2-4 levels 2 4 levels 2 4 levels 2 4 levels 2 4 levels 2 4 levels 2-4 levels 2-4 levels FMS ONE benefits Loading station options LSC LSC LSC, LSM LSC, LSM LSC, LSM, LST LSF, LSM, LST LSM, LST LSM, LST LSC, LSM Modular with flexible layout FMS ONE is fully configurable with a broad selection of modules to be built according to your specific needs. It's available in one or two sided configurations and is easily extendable afterwards. 2- to 4-level storage Logistics and material management FMS ONE includes the capability to manage raw material storage within the system. Several pallet types It is possible to integrate different types of machine tools and pallet sizes into FMS ONE. Full MMS5 integration A full set of integration options is available for FMS ONE. Machining center Stacker crane The exclusive, user-friendly Fastems MMS control handles all of your production scheduling and monitoring. It seamlessly interfaces with an ERP system and CNC programs generated by CAM software. MMS easily adapts to your changing production needs and, if you prefer, you can take total or partial control. Station commander Safety equipment Loading and material stations

8 CUSTOMIZED SYSTEMS The Fastems FMS is available in a wide range of configurations from a single machine tool cell to a complex FMS that includes several makes and models of machine tools, material management, integrated robot cells, warehouse functionality, and much more. FMS seamlessly integrates into your ERP and MES systems, as well as various machine tool interfaces. Seamless Integration Fully configurable A wide variety of modules provide the most profitable approach to manufacturing. You can also select different types of pallet setup areas for various products. Multiple machine tool types Your machine tool selection is not limited to one or two types of machine tools and pallet sizes. This gives you the ability to easily change or expand production using the same FMS. Extendability More than 80% are extended or modified after initial startup. You have the freedom to handle any future manufacturing scenarios. Material logistics It is possible to integrate your material logistics flow and billets within the system for automatic just-in-time delivery. Fastest pallet transfers It is the highest pallet transfers-per-hour system in the market. That gives you headroom for future extensions or workpiece changes, and the ability to use it as a base for high volume production. Lights out production With optimal quantities of pallets in storage, an assisting control system and proven reliability, it is easy to reach and monitor your output targets. User configurable widgets enable easy visualization of online monitoring, performance, key production figures, machine tool status and much more. The FMS integrates logistics and information flow within your manufacturing process. Beginning with a layout design that maximizes shop floor utilization, and including ERP and tool management, the CNC program management system accommodates everything from single machines to factory-wide systems with multiple machine tools and all manufacturing resources.

9 WIDE RANGE OF WORK SET STATIONS Our work set stations provide ergonomic solutions for loading and unloading your workpieces. Depending on the pallet and load size, the load can be transferred, lowered, rotated, and/or tilted to give the operator the best possible access to the workpieces. All loading stations can be accessed with an overhead crane for lifting parts and pallets. Occupational safety and health, as well as work environment and ergonomics, are taken into account. Various kinds of movable or static work platforms can be integrated into the loading area. Hydraulic or vacuum clamping can also be integrated into the loading stations, either with a manual hydraulic unit or a completely automated system. FEATURE LD MD MDR XMD HD XHD SPECIAL Load weight (kg) 700 1,500 1,700 2,500 6,000 10,000 Custom Machine pallet size (mm) Maximum load size (mm) ,250 1,000 1,600 Custom ,250 1,250 1,125 1,125 1,600 1,400 2,700 1,700 Custom Custom Load height (mm) 900 1,250 1,450 1,700 2,000 Custom Custom Stacker crane load handler Material pallets in the same system Number of integrated machine tools Brand of machine tools Parallellogram Telescopic forks Rotating handler Telescopic forks Telescopic forks Telescopic forks Custom Option Option Option Option Option Option Option Unlimited Any machine tool brand available in the market Number of pallet places Control system Unlimited MMS5 In addition to machining pallets it is possible to handle wooden and metal material pallets, gitterboxes, and customer-specific loads. Loading station flushproof LSF Manually operated, indexable rotating pallet table. Pallet sizes up to mm. Loading station compact LSC Manually operated, indexable rotating pallet table. Pallet sizes up to mm. Loading station moving LSM Horizontal transfer movement and indexable rotating pallet table. Typical pallets sizes starting from mm. Material station trolley MSP For one EUR pallet. Loading station tilting LST Horizontal transfer movement, tilting of the pallet, and indexable rotating pallet table. Typical pallets sizes starting from mm. Loading station lifting LSL Combined horizontal and vertical transfer movement and indexable rotating pallet table. Typical pallet sizes starting from mm. Material station conveyor MSC Two types: for one or two EUR pallets. Material station basic MSB For EUR or special pallets.

10 TOOL MANAGEMENT Central tool logistic automation is a system for centrally delivering and managing cutting tools for CNC machines. It enables the use of small tool magazines, eliminates human errors and reduces capital investment in tools. Machine control integration enables a machine tool to start machining even if all the required tools are not in its magazine. Only the first tools to be used in the NC program must be loaded. Tool automation delivers the rest during machining. FEATURE CENTRAL TOOL STORAGE (CTS) GANTRY TOOL STORAGE (GTS) Tools Up to 4,000 Up to 1,500 Robots Tool carriage capacity 5 5 Max tool weight 35 kg 35 kg Max tool length 650 mm * 650 mm * * Customization available Full tool life utilization The automated tool logistic system provides full tool life utilization. The tools are transported for maintenance at just the right time not too early, not too late. Larger amount of tools available If your production requires more tools than the number of spaces in the tool magazine, automated tool storage relieves your shop floor operators of repetitive tool carrying tasks. By equipping the machine tools with smaller tool magazines you also reduce investment costs. Tool usage simulation Fastems MMS5 software simulates optimal work queues for your machine tools. This functionality also applies to the cutting tools. With tool automation you can minimize the number of tools needed and calculate precisely what will happen next. You don t need to reserve all tools required for a specific job and machine tool at the beginning of a machining process. Share tools between CNC machines It s possible to reduce the number of identical tools to help cut down the total amount of tools used, without sacrificing production flexibility. This is especially helpful with expensive, specialized cutting tools. Real time information of needed tools MMS5 tool management streamlines the flow of information. It eliminates paperwork for tool differences or future tool replacements. Plus you have full integration with the FMS control, including priority settings and standardized interfaces for many presetting devices. Extend your lights out production period When cutting tools are no longer a production bottleneck, you can extend your lights out period even further. Central tool storage (CTS) places a tool storage container on the factory floor next to the machine tools it services (as pictured above). A dedicated robot manages the tools in the storage container while one or two additional robots move on guideways above the machines to place the tools into the appropriate machine tool holders, and return replaced tools to storage Gantry tool storage (GTS) places a tool storage container above the machine tools and uses a single robot to both manage tool storage and to transfer tools between the machines and the tool storage container.

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12 FPC PLUS ROBOFMS FPC PLUS is based on the proven Fastems FPC platform. FPC is a standard FMS constructed from container modules, allowing the integration of up to three machine tools per system. Thanks to its modular and compact construction, FPC is also a profitable investment when integrating only one machine tool. With FPC PLUS you can add optional customer specific modules including deburring and washing operations, tracking features and much more. The RoboFMS enables automation for a wider range of machine tools, including machine tools without automatic pallet changers. Additionally, it's easy to integrate washing machines, marking machines, measuring devices and other production equipment. Configurable Whether you need standard automation or a more advanced system, including full process integration, modular FPC PLUS is your fully configurable solution. Control MMS5 control links your process and FPC PLUS. It knows and shows everything that is happening and allows you to take complete control. In addition MMS5 lets you predict, plan and monitor your production cell. Agile Start with one machine tool, then extend with additional applications as needed. You have the freedom to handle any future manufacturing scenarios. Connect Using ERP or CAD/CAM? MMS5 links your shop floor to these systems. FPC PLATFORM FPC-750 FPC-1000 FPC-1500 FPC-3000 FPC-7500 Load weight, including pallet (kg) 750 1,000 1,500 3,000 7,500 Nominal machine pallet size (mm) or or or or 1,000 1,000 1,000 1,000 or 1,250 1,250 Load size (X Z mm) ,050 1,000 Ø 1,600 Ø 2,300 Load rotational diameter (D mm) 800 1,250 1,250 1,600 2,300 Load height, including pallet (H mm) 900 1,100 1,200 1,800 2,000 Storage capacity by container unit Excellent floor space utilization RoboFMS gives you considerable freedom for workshop layout design. You can install the robot in a stationary location or on a linear track, and position devices and buffer storage where needed. Combine several device types Now have machine tools, finishing cells, measuring devices, and your complete logistic chain under one automation system. Lights out production With an optimum quantity of pallets stored, an assisting control system and proven high reliability, RoboFMS is ideal for unattended operation. Total logistics management RoboFMS makes it possible to integrate your material logistics flow and billets with your FMS for automatic, just-in-time delivery. Improved reach and accuracy Adding an industrial robot opens up new possibilities for handling difficult to reach production equipment and zero point fixturing. It also provides excellent operator clearance for these devices. Complete FMS control RoboFMS is equipped with MMS5, the industry s leading FMS control. MMS5 ensures seamless device and system integration, NC, fixture and tool management.

13 MANUFACTURING CELLS For medium and high volume production we provide efficient and reliable gantry and robot solutions. Optimally matched handling systems and material buffers enable continuous and reliable round-the-clock manufacturing for a wide range of workpieces. Gantry systems Clear access and space saving Unobstructed machine tool access makes setups and monitoring easy while reducing downtime. Loading from the top saves valuable floor space. Also for low ceiling heights Fastems telescopic axis module is the perfect solution for facilities with restricted ceiling height. Optimal material flow Our extensive range of material buffering systems lets you choose a gantry solution that fits to your process flow precisely. Customized solutions Our modular system gives us the flexibility to design customized solutions whenever you need them. Robotic handling cells Single pass manufacturing process The agile movement capabilities of a robot enable you to integrate multiple processes into a true, single-pass manufacturing cell from raw material to ready-to-pack. We can integrate a wide range of additional processes such as deburring, drilling, cleaning, marking, measuring and much more. For an optimal material flow The wide range of Fastems material buffering systems allows you to seamlessly integrate robotic loading into your process flow. Integration on multiple levels Powerful Fastems software maximizes the performance of your manufacturing system with optimum control and transparency. Independent integrator Using our 30+ years of experience, we concept, design, build and deliver robotic solutions that incorporate the best, proven technologies, regardless of the brand of manufacturing equipment involved.

14 Robotic finishing cells The right spindle type for the right process Our automated solutions for grinding, polishing, deburring, brushing and more deliver perfect results, every time. Robotic finishing cells work continuously and reliably to produce the maximum number of precisely finished parts on each shift. It's a brilliant finish to your metal-cutting process. Ergonomically better Finishing tasks are among manufacturing s most challenging, often performed in dusty conditions while in uncomfortable positions and using noisy, vibrating tools. Having robots perform these jobs frees your workers for more productive and less physically taxing activities. Consistent quality Because industrial robots are highly repeatable and reliable, Fastems robotic solutions ensure that your 1,000th part is just as good as your first. The best of both worlds The finishing or deburring process is always tailored to your specific application. That s why Fastems offers both pneumatic and electric tooling for maximum process efficiency. Features Available process types: Tool-to-Part and Part-to-Tool Several material feeding options based on process type magazines, trays, conveyors, servo station Readymade interface for FMS Tool management system Sound- or splash-proof housing for maximum ergonomics Pneumatic spindles Programmable tools compliance to compensate for differences. For example: part castings Each spindle typically has one tool Wide selection of spindles available for different applications Typically for applications where tool amount is moderate Electric spindles One spindle can handle many tools For applications requiring a large amount of tools or where new tool implementation is frequent Good spindle power output Traceability of control variables Programmable rpm Optional accessories Measuring probe for part referencing Dust extraction systems Machine vision for optical inspection Force control systems Robocoat for dusty application Coolant system for wet processes Quality control systems Fire suppression systems ATEX proof

15 MANUFACTURING SYSTEMS FOR HIGH MIX PRODUCTION The heart of the system is the Fastems control software. It enables parallel manufacturing of multiple orders while ensuring that production runs uninterrupted. Management of resources The system control makes it easy to handle the various manufacturing resources needed. Missing resources are indicated, thus enabling trouble-free manufacturing. Easier production planning Our control system makes is easy to plan the production for the integrated system. You have an overview of all orders in the system and the necessary resources for each. Optimizing output without losing flexibility The system can adapt to changes in the manufacturing environment. This means, for example, that an order with missing resources does not stop the line completely, instead the next order is processed. Integration of manufacturing processes You can integrate many processes under one system. This helps, for example, to eliminate unnecessary storages and transfers between processes. You can achieve extended unmanned periods without making resource planning more complicated. By using an automated material storage system, you can extend unmanned production time to an entire weekend, for example. Advanced software options combined with system hardware forms a true productivity solution for high mix manufacturing.

16 MANUFACTURING LINES FOR HIGH VOLUME PRODUCTION Many components must be perfectly aligned with one another to keep material flowing properly. That s why we develop the most effective interlinking solution for your automated production. We base the solution on batch size, the variety of workpieces, cycle time, available space and logistical considerations. Output is everything In high volume manufacturing what is most important is constant and high quality output. This is achieved by paying attention to every detail to form the best solution for each customer's process Service world wide Fastems 8760 support is there for you aroundthe-clock, 365 days, 8760 hours per year. Optimal material flow Automated workflow and processes increase productivity and reduce costs by shortening lead times, eliminating extra transfers, and reducing work-in-progress (WIP). Space savings Automating material movement between processes and eliminating storage of work-inprogress outside the interlinking system, saves considerable factory floor space. Maximize the value of your manufacturing line with robot cells for additional operations such as deburring, assembly, measuring and more.) Bind manufacturing processes together with our interlinking solutions for maximum output.

17 We are Fastems. We are here for you. At Fastems, we believe that building and maintaining a strong manufacturing base is essential for the development of our society and the well-being of the people. That is why we do everything in our power to increase the competitive advantage of our customers and to make their production facilities as efficient, profitable and forward-thinking as possible through intelligent digitization and process automation. Systems that have been developed with the health and safety of your personnel in mind 24/7 support to ensure maximum productivity during all 8,760 hours of the year We look forward to helping you determine the potential of your manufacturing processes and to finding a solution that is right for you! Decades of industry experience and more than 4,000 successfully installed systems worldwide Systems that optimize your time cycles, reduce costs and improve the usability of your existing machinery Subject to technical changes Factory Automation Systems vers_01_en 07/2018