Erik Metternich - Bystronic

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  • 1. Mikrocentrum Thema middag:Geld verdienen met kleineseries plaatwerkErik Metternich – Sales Manager Bystronic Benelux BVEindhoven – 22 mei 2012Bystronic • Founded in 1986 • Field of activity: Sheet Metal Processing Systems • Headquarters: Niederönz (CH) • Since 1994 part of the Conzzeta Group© Bystronic | 05 .2012
  • 2. Core ActivitiesLaser WaterjetCutting Cutting Bending • Process chain: cutting - bending • All from a single source • For all flat materials and all shapesHandling & Software & Services &Automation Control Support • Automation of entire material and data flow • Increased productivity • Cost efficiency© Bystronic | 05 .2012Research and Development• Bystronic is master of all key technologies and components• Every 10th employee is involved in the development of products and services© Bystronic | 05 .2012
  • 3. Key Figures 2011• Sales 500 million CHF (408 Mio. €, 563 Mio. $)• Employees 1492 – Europe 1018 (of which 510 in Switzerland) – Americas 110 – Asia 364• Apprentices 98© Bystronic | 05 .2012Worldwide just around the corner 4 manufacturing locations 26 sales and service companies© Bystronic | 05 .2012
  • 4. Bystronic in Niederönz (CH) • Headquarters • Development and manufacturing of laser and waterjet cutting systems • Applications and demon center • Bystronic Sales Ltd© Bystronic | 05 .2012Bystronic in Gotha (D) • Development and manufacturing of Xpert and Hämmerle pressbrakes • Application and demo center© Bystronic | 05 .2012
  • 5. Bystronic in Tianjin (China) • Development and manufacturing of pressbrakes • Development and manufacturing of laser cutting systems for local markets© Bystronic | 05 .2012Bystronic in Braşov (Romania) • Refurbishing Center for laser cutting systems© Bystronic | 05 .2012
  • 6. Product PortfolioLaser cutting and automation (I)BySpeed Pro Byspeed ByVentionBystar Bystar LBySprint Fiber BySprint Pro/BySprint© Bystronic | 05 .2012Product PortfolioLaser Cutting and Automation (II)ByTrans / ByTrans Extended BySort BycellCross BycellLine© Bystronic | 05 .2012
  • 7. Product PortfolioWaterjet cutting ByJet Smart ByJet Classic ByJet Classic L ByJet Pro ByJet Pro L© Bystronic | 05 .2012Product PortfolioBending Hämmerle 3P Xpert Robot applications Xact Xcel© Bystronic | 05 .2012
  • 8. Latest DevelopmentsBENDINGFast Bend+Effective efficiency
  • 9. Effectiveness can be efficientComparison safety systems• AKAS manual Speed changing Fast speed Standard safety system on point area many machines 16-25mm Working speed area AKAS manuell 0 [sec] 3 6 MaterialApp. 5,5 Seconds cycle time Lower tool© Bystronic | 05 .2012Effectiveness can be efficientComparison safety systems Speed changing Fast speed point area AKAS III motorisch 9-12mm Working speed area AKAS manuell 0 [sec] 3 6 MaterialApp. 4.2 Seconds cycle time• AKAS III motorized Lower tool Optional on many machines© Bystronic | 05 .2012
  • 10. Effectiveness can be efficientComparison safety systems Speed changing Fast speed point area Fast Bend (manuell) AKAS III motorisch 9-12mm Working speed area AKAS manuell 0 [sec] 3 6 MaterialApp. 4.2 Seconds cycle time• Fast Bend Lower tool Standard safety system on Xpert© Bystronic | 05 .2012Effectiveness can be efficientComparison safety systems Speed changing Fast speed point area Fast Bend+ Fast Bend (manuell) AKAS III motorisch AKAS manuell <4mm Working speed area 0 [sec] 3 6 Materialapprox. 3.4sec bending cycle time• Fast Bend+ Lower tool Standard for 3P and optional for Xpert© Bystronic | 05 .2012
  • 11. Effectiveness can be efficientFast Bend+Automatic height adjustment 100 [%] 110 120+ Higher safety+ Faster job change+ Also for lateral tool changes© Bystronic | 05 .2012Effectiveness can be efficientComparison safety systems• ROI AKAS AKAS III Fast Bend Fast Bend+Speed changing <25mm <12mm <12mm <4mmTime saving per bend 0 1.2s 1.2s 2sSet up time safety system 60s 40s 60s 20sBend per hour* 400 480 480 560Bends in % 100 120 120 140ROI after (in Months) 0 7 0 4Capitalised value 0€ 14.000€ 15.000€ 30.000€ *Oberer Todpunkt = 100mm, 90°, Materialstärke T=2mm, V=16mm, Wartezeit im UT 0,5sec, Xpert 150t, 20 Werkzeugwechsel pro Schicht, eine Schicht pro Tag, 5 Tage die Woche, 40% Leerlauf, Werkzeugwechsel von 175 auf 250mm Höhe© Bystronic | 05 .2012
  • 12. Optical Bend Guiding SystemFor the fastest bending process worldwideLED basedOptical Bend Guiding System• Easier tool positioning 1 2 e.g. 2 tool positions over bending length© Bystronic | 05 .2012
  • 13. LED basedOptical Bend Guiding System• Optically guidance through the bending process – Easier tool positioning – Clear back gauge position indication – More effective station guiding – Opened clamping information – Error indication – End of job indication© Bystronic | 05 .2012LED basedOptical Bend Guiding System• Clear back gauge position indication 1 2 Indication of back gauge finger position© Bystronic | 05 .2012
  • 14. LED basedOptical Bend Guiding System• More effective station guiding 1 2 Indication of next bending station© Bystronic | 05 .2012LED basedOptical Bend Guiding System• Opened clamping information Flashing stations or flashing over bending length© Bystronic | 05 .2012
  • 15. LED basedOptical Bend Guiding System• Error indication Light bars are indicating in direction of the control© Bystronic | 05 .2012LED basedOptical Bend Guiding System• End of job information Open flashing over complete bending length© Bystronic | 05 .2012
  • 16. Energy SaverBystronic XpertBystronic Energy Saver 30% less energy consumptionChange of product and still unique… Up to 3% less energy consumption with START-STOP© Bystronic | 05 .2012
  • 17. Energy Saver versus conventionalEnergy consumption Consumption over time with Energy Saver (Xpert) kWh % Consumption over time conventional machine 100% 50% Top dead centre Approach speed Bend Return Top dead centre Time© Bystronic | 05 .2012Energy Saver versus conventionalEnergy consumption Consumption over time with Energy Saver (Xpert) kWh % Consumption over time conventional machine 100% Up to 30% energy saving 50% Top dead centre Approach speed Bend Return Top dead centre Time© Bystronic | 05 .2012
  • 18. Energy Saver versus conventionalNoise Noise with Energy Saver dB Noise conventional machine 100 [Noise of a rock concert] 70 40 Top dead centre Approach speed Bend Return Top dead centre Time© Bystronic | 05 .2012Energy Saver versus conventionalNoise Noise with Energy Saver dB Noise conventional machine 100 [Noise of a rock concert] Less noise – less stress 70 40 Top dead centre Approach speed Bend Return Top dead centre Time© Bystronic | 05 .2012
  • 19. Energy Saver versus conventionalLess wasted heat 100 50 Energy Saver Conventional Heat % 0 Conventional Energy Saver• Less heat – less climate costs* *40% Standby time (some competitors assume 90%) 1 shift, 220 working days, 150t machine, 3kW power consumption of a conventional machine in stand by, 24Cent/kWh© Bystronic | 05 .2012Let’s save energy.
  • 20. LAMSQuality up - Cost downBystronic XpertLAMS – Quality up Cost down© Bystronic | 05 .2012
  • 21. Bystronic XpertLAMS – Quality up Cost down• Customer goal: First part, right part!• Problem: Differences in … Material 1 Material 2 Tensile strength / Quality Same Sheet 1 material Sheet 2 Sheet thickness /batch Laminating direction Spring back© Bystronic | 05 .2012Bystronic XpertLAMS – Quality up Cost down Mode Compensation Special cycle 1 • Angle control • Non LAMS ON • Sheet thickness • Geometry errors 2 • Angle control • Machine moves up by data LAMS SB with DB • Sheet thickness base SB value plus 2° • Geometry errors • Sheet must be slightly guided • Spring back 3 • Angle control • Machine moves 20° up. LAMS SB learn DB • Sheet thickness • Only used for data base learn • Geometry error cycle for new materials • Spring back© Bystronic | 05 .2012
  • 22. Bystronic XpertLAMS – Quality up Cost downWITHOUT Data Base startNo LAMS 90.0°  15 S  5S 5.8 S 5.8 S 95.5° 10 S  BACK GROUND INFORMATION Y 6mm P7 V40 ??steel?? DB© Bystronic | 05 .2012Bystronic XpertLAMS – Quality up Cost downWITH Data Base startNo LAMS 90.0°  15 S  5S 6.1 S 6.1 S 90.6° 10 S  +0.0s BACK GROUND INFORMATION Y 6mm P7 V40 steel DB© Bystronic | 05 .2012
  • 23. Bystronic XpertLAMS – Quality up Cost downWITHOUT Data BaseWITH Spring Back Measurement startLAMS - Mode 3 90.0° 16 S  6.1 S 15 S  5S 90.1° 10 S  +9.9s BACK GROUND INFORMATION 6mm P7 V40 ??steel?? DB © Bystronic | 05 .2012Bystronic XpertLAMS – Quality up Cost downWITH Spring back value in Data Base startWITH Spring back measurementLAMS - Mode 2 90.0°  15 S  5S 6.1 S 90.1° 11.2 S 10 S  +5.1s BACK GROUND INFORMATION 6mm P7 V40 steel DB © Bystronic | 05 .2012
  • 24. Bystronic XpertLAMS – Quality up Cost downWITH Spring back value in Data Base startLAMS - Mode 1 90.0°  6.1 S 15 S  5S 7.5 S 90.1° 10 S  +1.4s BACK GROUND INFORMATION 6mm P7 V40 steel DB © Bystronic | 05 .2012Bystronic XpertLAMS – Quality up Cost downWITH Spring back value in Data Base startLaminating direction 90° changedLAMS - Mode 1 90.0°  15 S  5S 6.1 S 7.6 S 89.8° 10 S  +1.5s BACK GROUND INFORMATION 6mm P7 V40 steel DB © Bystronic | 05 .2012
  • 25. Bystronic XpertLAMS – Quality up Cost downWITH Spring back value in Data Base startSheet was 0.5mm thicker!LAMS - Mode 1 90.0°  6.1 S 15 S  5S 7.4 S 90.1° 10 S  Sheet 1 Same material Sheet 2 +1.3s BACK GROUND INFORMATION 6mm P7 V40 steel DB © Bystronic | 05 .2012Bystronic XpertLAMS – Quality up Cost downMode Compensation Special cycle 1 • Angle control • Non LAMS ON • Sheet thickness • Geometry errors 2 • Angle control • Machine moves up by data LAMS SB with DB • Sheet thickness base SB value plus 2° • Geometry errors • Sheet must be slightly guided • Spring back 3 • Angle control • Machine moves 20° up. LAMS SB learn DB • Sheet thickness • Only used for data base learn • Geometry error cycle for new materials • Spring back© Bystronic | 05 .2012
  • 26. Bystronic XpertLAMS – Quality up Cost down• All parts good parts, thumbs up!• Automatic quality control• No doubt, no stress© Bystronic | 05 .2012Bystronic XpertLAMS – Quality up Cost down• Save cost on material• Lower labour cost© Bystronic | 05 .2012