The specialists at MAG IAS GmbH have created an innovative, future-oriented manufacturing solution by combining their highly productive machining centers in the SPECHT range with proven automation systems. This will accommodate the rising demands for further automated, yet highly flexible manufacturing. The manufacturer is presenting a corresponding system for the first time at the AMB 2018 trade show in Stuttgart (Hall 6, Stand B11). 
Those who will benefit from fully automated, yet highly flexible manufacturing include the likes of automobile manufacturers and suppliers and contract manufacturers in general engineering, aerospace and mold making. "Our customers can produce parts in batches in a highly productive manner without operators, but they can also manufacture individual pieces extremely flexibly and thus work with particular overall efficiency", states Gerald Mies, President Milling & Factory Automation.  

More flexible, faster switching between batch and single-piece production  
Depending on the order situation, the system can produce batches of the same parts in quick succession or use its automated setup procedures to produce varying single workpieces. This is successful over the course of many hours completely without operators. Manufacturing companies can therefore operate extremely effectively to make productive use of night time and weekend shifts as so-called ghost shifts. 
This is taken care of by a sophisticated combination of the SPECHT 600 machining center with pallet changer from MAG, an industrial robot from KUKA suspended on a gantry, a gripper changing and VERO-S zero-point clamping system from SCHUNK, intra-company logistics via unmanned transport vehicles (AGV) from KUKA and cloud-based Sinumerik controls from Siemens with integration of the robot controls into the machining center's CNC controls. The specialists at MAG IAS arrange the respective components to be application- and customer-specific. It is beneficial that the modular design of the system enables it to be matched to the production areas. The system can even be reassembled in different configurations as necessary. This enables flexible coordination to the operating company's current needs. It also includes the integration of additional machining operations, such as deburring, cleaning and conservation or measuring and inspection stations in the robot's workspace for quality assurance. 

An AGV involved in the entire production process 
An AGV moving autonomously and flexibly in the area brings blanks to the robot's workspace and then fetches finished workpieces. Video cameras detect the parts and their position, so that the robot can grip them securely and accurately. The latter selects matching grippers from its supply then loads and unloads the pallets on the machining center's shuttle table. This ensures minimum downtime during workpiece change. Automatic gripper change also means that the robot can be used to remove tools from an external auxiliary magazine and insert them into the machining center's magazine, for example, or as an option for introducing a blower to clean fixtures and workpieces. This contributes substantially to the production system's ability to manufacture even the most varied parts as single-pieces over many hours completely without operators. 

Digital twin with 3D simulation for minimum production startup times
This production system is managed by Sinumerik CNC controls. It can use cloud-communication for data transmission. Users are therefore well equipped for the emerging Industry 4.0 concept. It is especially convenient and
beneficial that a dialog in the RunMyRobot software can be used to simply program the robot's working movements directly at the machining center. This significantly reduces programming times. Such integration is enabled via the universal KUKA.PLC mxAutomation communication interface. Communication with the KMP1500 is wireless. Further AGVs can be added to KUKA FleetManager at any time. This architecture enables scalable solutions, especially for small and medium-sized companies. 
Integrated 3D simulation in conjunction with a digital twin of the entire system guarantee maximum process reliability. All production processes can thus be programmed and tested in advance. This relates on the one hand to the functions of machining center, robot and optionally integrated post-processing or measuring and test stations. On the other hand, however, the efficiency data can also be tested and verified for the required productivity and availability prior to physical commissioning. This significantly shortens the time from planning these automated production systems through to production flow. 

Proven, reliable components with global service 
Machine manufacturer MAG IAS acts as a system supplier to assume overall responsibility for the configuration and realization of customer-specific production systems. It uses proven components from several globally active manufacturers to do this. This firstly has the outstanding advantage that the components work reliably, and secondly that a qualified service is available worldwide. It minimizes downtimes and optimizes availability to enable manufacturing companies to work productively and efficiently.