DMG MORI digitized their spindle assembly line with Tulip
CASE STUDY

DMG MORI

DMG MORI uses Tulip to digitize their spindle assembly line

DMG MORI

DMG MORI is a leading international manufacturer of machines and machine tools. Serving customers in over 42 industries and 79 countries, DMG MORI strives to be “Global One Company”–leveraging the best of their German and Japanese heritage in our modern interconnected world.

DMG MORI builds cutting-edge innovation into each of its products. As digital technology becomes essential to manufacturing, DMG MORI is taking active measures to maintain its position as a leader in integrated digital innovation.

 

Customer

DMG MORI

Industry

Machine

Location

Pfronten, Germany

Customer Website

The Challenge

DMG MORI produces the spindles for many of their machines in-house. Each spindle is the product of a complex assembly. Spindles move through a single-piece flow process spanning over a dozen stations.

Every station includes highly variable picking procedures and quality checks. While operators have access to paper schematics and standard work requirements, existing quality measures were time consuming and prone to error.

Work was recorded on paper forms, making it difficult to track progress in real time. When defects arose, they were recorded on additional paper forms. Without real-time data, finding patterns in production data was slow and prone to error.

Finally, DMG MORI’s lines adhere to strict Takt times. Without visibility into the work performed at each station, the company lacked the ability to identify bottlenecks and properly balance lines. Current workflows made it difficult to track WiP through the line.

“Our spindle line assembly consists of over 16 stations. It’s important that the operator knows exactly which task they need to perform to complete the job.”

-Reinhard Musch, Managing Director of DMG MORI’s Deckel-Maho operations

The Solution

DMG MORI digitized their spindle assembly line with Tulip

Spindle Assembly Apps

Their applications guide operators through each step of the assembly. Relevant Schematics are included at every step, ensuring that each operator has the information they need at their fingertips. At stations where operators must pick from a wide array of parts, pick-to-lights guide operators to the correct part.

DMG MORI’s spindle assembly applications eliminated paper forms from the line and provided feedback to the operators in real time.

Standard Work at Your Fingertips

For each step in the assembly, DMG MORI embedded the schematics necessary for operators to correctly understand and execute their work. Instead of paging through static, paper forms, operators can immediately access the correct drawings and instructions. Further, they are able to rotate, zoom, and expand instructions as necessary, improving the accuracy and speed of each step.

Digital work instructions at the spindle assembly line at DMG MORI
In-app defect reporting using Tulip at DMG MORI's spindle assembly line

In App Defect Reporting

Should defects arise, each step of the application gives operators the option to create a defect report. These reports are customized to the specifics of the spindle line. When a defect is reported, a message is automatically sent to a shift supervisor, who is able to initiate the proper corrective action.

“Tulip helps us determine the root cause of problems with absolute certainty,” Musch reported.

The Bottom Line

62% reduction in reported defects

20% production increase

10% reduction in failure rates

4 weeks time to value

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