1. special Advertorial
On a Mission to Modernize
the Thai
Manufacturing System
You will meet few people who seem as passionate about what they do as Uli
Kaiser, EMAG’s Business Development Manager for South East Asia. In fact, he
even admits to us that he is somewhat like a missionary; but instead of converting
people’s religious beliefs, Uli sees himself as converting them to new and more
efficient manufacturing practices.
W hen we met Uli, one of the first things
he tells us is how he wishes to change
the culture of production managers
from one where they rigidly stick to the
traditional “nagare” process, to one where they
one-piece flow of the workpiece, and is split up
into simple steps with simple machines, usually
arranged in a U-shape.
Many manufacturers will claim that the
nagare method has served them well for many
that are costing manufacturers in terms of
productivity, efficiency, and ultimately money.
While many managers are aware of the problems
with the nagare concept, many do not know
how they can change the ways they do things
start to reach towards a modern “world class” years, and that there is no need for any change, in order to eliminate these problems. He informs
manufacturing method. In the nagare concept, but Uli opens our eyes and walks us through the us how Thai manufacturers are right now at a
the production process is thought of as a many problems with this traditional approach crossroads where it is time to make a decision
68 NOVEMBER - DECEMBER 2011
2. on which type of production system they wish to from vibrations are minimized with EMAG’s A further critical aspect of a world-class
follow for at least the next 10 to 15 years. It is Mineralit stone bed and stable structure, and manufacturing system is, according to Uli, the use
time for manufacturers to decide whether they problems with temperature are minimized with a of high-powered machines. Uli tells us that EMAG’s
wish to continue with the traditional approach or cooling system for the whole machine, and not machines have three times the power of classic
to move forward with new and more productive just the spindle. machines, which gives them three times the speed
methods. Another typical feature of a nagare system is of these machines as well. This power, in turn,
Uli describes to us how many of the problems the use of numerous basic machines for means that tools can also cut deeper, resulting in
of the nagare approach come from its carrying out the different steps of the process. This much faster machining; plus, in addition to this,
over-reliance on the operators. Further explaining leads to constant re-clamping as the tool wear that is equal to that of machining at
that while labor expenses may not be very high workpiece is moved from machine to machine, slower speeds.
right now, they are going up rapidly, plus the costs adding compound errors at each step. Uli Uli went on to explain how as well as being
of labor do not merely come in the form of explained that with a world-class machining more powerful, EMAG’s machines were more
wages, but also come in from increased mistakes method, many different processes are integrated efficient as well. He gave examples of how EMAG’s
and lower productivity when compared to into one machine. This allows turning, drilling, machines could operate 24 hours per day,
automated methods. With the nagare milling, grinding, fine boring, reaming, stamping compared to an average of 20 hours per day for
method, the operator is responsible for almost and gauging etc. to be carried out on one classic machines. With classic machines displaying
everything, from setup to carrying out offsets, machine, with the workpiece not needing to be an average of 265 days’ operation per year, Uli
changing over pallets and workpieces, and removed and then clamped into another told us that his EMAG machines could reach
finally checking the quality of every piece. machine for each process. This reduces both the operating times of 300 to 350 days per year. All
“During the middle of the day, operations may compound errors that develop from constant of these efficiencies add up to a technical
be able to be carried out effectively, but by the re-clamping, as well as the total number of availability (TA) of 98%, as well as an overall
end of the shift, or at 3 am in the morning, the machines, reducing total capital costs. equipment efficiency (OEE) of 85% in comparison
operator will not be working to their maximum Uli provided us with an example where using to an OEE of 70% for classic machines.
potential,” explains Uli. the nagare method manufacturers would have In order to continue spreading his message,
In contrast, he tells us how the EMAG needed about 48 classic machines, whereas with Uli has joined forces with SECO Tools and Walter
philosophy is to completely remove the worker a world-class method using advanced machines to host a technical presentation at Metalex Thailand
from as many tasks as possible. This means there only about 12 machines were necessary, saving 2011 on 21 December 2011, where he, along
is no manual offsetting, and integrated gauging the factory significant floor space. With with some of EMAG’s top technical specialists,
using an inbuilt probe makes automatic offsets in automated systems and fewer machines, fewer will be demonstrating EMAG’s philosophy as well
order to implement process capability, where workers are required. Processes that would as its machining, joining and laser welding
geometries are kept not just within acceptable previously have used four operators, now only need technologies that are commonly used in the
tolerances, but within such tight limits that only one to two. Another added benefit of fewer production of a whole variety of components for
about one in a hundred workpieces even need machines is less energy usage (around 30% less engines, powertrains and chassis. Those interested in
to be inspected. This is in contrast to the according to Uli) and less maintenance as well hearing more about world-class machining methods
traditional nagare process where almost every (also around 30% less); thereby providing can contact Uli at +66 87 146 8800 or e-mail:
workpiece requires inspection. In addition, problems manufacturers with significant process savings. ukaiser@emag.com.
NOVEMBER - DECEMBER 2011 69
