Flexible robot automation system
for variable-mix / variable-volume production

Higher Productivity through Automation

TSUZUKI MANUFACTURING has been proactively enhancing its production through automation, including the use of an automation system with specialized machines for the manufacturing of automotive parts. In 2018, the company newly introduced an automation line for the mass production of stator shafts with 3x NRX 2000 and 5x i 30 V machines by DMG MORI - a combination of turning centers with 2 parallel spindles and 2 turrets and vertical machining centers with automatic tool change on both sides. By this, the company was able to surpass its old production line both in terms of production volume and machining accuracy.

To further increase productivity, TSUZUKI MANUFACTURING was also searching for an efficient solution to automize its high-mix production for construction machinery parts. It is more difficult to automize variable-mix and variable-volume production, but the company found that the highly flexible and precise solutions of DMG MORI meet all requirements and finally introduced an automation system that consists of the self-driving robot WH-AMR 5 and 2x NTX 1000 2^nd Generation turn-mill centers.

Variable-mix / Variable-Volume Production with the Self-driving Robot WH-AMR 5

"We were looking for an automation system that would allow robots and operators to coexist and work together. The automation system by DMG MORI has enabled flexible workpiece transfer between processes and made our production safer and more efficient.", says Mr. Kazuhumi Miyashita, the Director and General Manager of the Engineering Headquarters at TSUZUKI MANUFACTURING. In this system, the NTX 1000 integrates all required machining processes into one machine, while the WH-AMR 5 automates all steps in the process chain, including workpiece transfer, workpiece loading to the machine, unloading of finished workpieces and transfer to the washer, reducing setup and maintenance time. As a collaborative robot system, WH-AMR 5 is cost effective since it enables long unmanned operation and 24-hour production without requiring a safety fence or additional safety devices. Furthermore, WH-AMR 5 can take care of multiple machines in one area to handle various tasks that go beyond workpiece handling, including tool and fixture transfer, measurement and more.

Pursuing Technological Innovation and Quality Excellence

"DMG MORI has an extensive lineup of mill-turn, turning and machining centers and makes excellent automation proposals that include the optimal peripherals and machining solutions. I believe that their robot automation systems are one step ahead of other companies.", says Mr. Miyashita about his experience with DMG MORI. Furthermore, he shares his vision for the future: "We will continue to evolve our automation systems for variable-mix variable-volume production to flexibly respond to customers' demands. We will also strive for higher quality through added values, such as taking measurements during workpiece transfers." With their accumulated know-how, TSUZUKI MANUFACTURING will continue to pursue technological innovation and quality excellence to achieve further growth in a fast-changing world.