DESMA HIGHLIGHTS INDUSTRY 4.0 IN A HISTORIC STEEL MILL
On the eve of the K Trade Fair, DESMA opened this year's dual trade fair appearance under the motto "Enter New Spaces" in the “Glühofenhalle”, the forge hall, in the Böhler area.
This time, DESMA presented its services with a new dual trade fair concept at K 2019. Customers signed up in hall 16 at booth F56. In small groups, visitors were taken to an exclusive venue by shuttle bus - a former steel mill in the west of Düsseldorf - where they were welcomed in a cool lounge. On 400 m², the company had built up an entire machine park. In the spacious hall, visitors experienced individual presentations of DESMA technology live. DESMA experts demonstrated the systems and explained the technical details.
On 15 October, DESMA invited the press and VIPs to the opening. In his speech, DESMA Managing Director Dr. Harald Zebedin explained the complex challenges facing the company. Uncertainty is the new megatrend. The automotive industry and world trade are undergoing a radical change and DESMA is also feeling the effects. Nevertheless, the targets set out remain achievable. By 2022, a market share of 50 per cent or about € 180 million in sales is sought to be achieved, DESMA wants to gain at least 50 new customers per year and generate sales of € 50 million in the business of customer service, spare parts, rebuilds and mould making.
Sales Director Harald Schmid explained: “DESMA is a hidden champion, that is an unknown global market leader.” He said it was on its way to becoming a mechanical engineering service provider that integrates itself into the processes of its business partners. This reorientation is supported by the SmartConnect4.U Eco System presented at the K for the first time.
Necessary changes in uncertain times
Dr. Stefan Loheide, Head of Research and Development at BOGE Elastmetall GmbH, gave a comprehensive overview of the economic factors of influence in his presentation on the trends in automotive development. The economic focus is shifting towards the East, resources are becoming scarcer and new mobility solutions are urgently needed, but it is not yet clear what they will look like. The future has become more confusing and this creates uncertainty. BOGE faces its challenges with a consistent change strategy. Applied to the development department of an automotive supplier, this does not only mean managing the existing business optimally, but also initiating a regulated process for improvement and innovation at the same time. This makes it easier to react flexibly to changing conditions.
Experience technology first hand
The particular focus of the systems on show was on making production more flexible, for example by converting systems at short notice. One exhibit was a D 968.250 ZO Benchmark 750 S3 with FlexCell. It was impressive to see how quickly the DESMA technicians on site disconnect the FlexCell automation cell from the machine in just a few simple steps and how easily the 3-ton cell was then be manoeuvred on an air cushion. In less than three minutes it was reconnected - again ready for operation. The system produced a moulded rubber article with an overmoulded SmartIdent RFID chip - for the first time.
Another D 968.250 ZO BENCHMARK 750 S3 with QuickLock quick clamping system was also installed in the Glühofen hall. This machine is the first to produce moulded rubber articles with overmoulded SmartIdent RFID chips. The mould is changed in just a few minutes. The mould clamping is ensured even in the event of a power failure or a complete drop in hydraulic pressure. A mould change with a hot mould was presented live.
Aside from that, the focus of the machines on show was on efficiency and performance. In addition to a number of other features, a 969.300 SEALMASTER S3 was equipped with a hydraulic PerformanceKit. This significantly improves all movements of the mould carrier and the hydraulic core lifters. As a result, cycle times are reduced by 2.5 to 5 seconds, depending on the motion sequence.
The fourth system on display, a D 969.100 Z S3 with FIFO-C high-pressure injection unit and PartnerFlexcell, is an example of efficient small series production. The swing-out extruder unit facilitates a quick change of the mould or compound, made possible by the FIFO-C injection system with 100 cm³, 2,450 bar with integrated PlastControl. If required, the plasticising screw can be very quickly removed for inspection or cleaning. In HTV silicone applications, the new Cartridge+ plug unit allows the material to be changed easily and largely without losses.
This system was presented with a PartnerFlexCell, which was equipped with a collaborating six-axis robot system and offered a new CE-compliant safety concept as well as three-dimensional scanner protection. This enables robots, machine and people to work together without mechanical safety guards. Besides, the design of the PartnerFlexCell allows its easy transfer to other machines. Thus, either pure machine operation or plant operation is possible by switching over. This machine also used a ZeroWaste ITM system with a mould for the production of small rubber-metal articles. The metal parts are fed into the mould by the robot.
DESMA MAKES THE FUTURE EFFICIENT
At K 2019, DESMA will show how the latest machine technology combined with individual service offerings can simplify production.
DESMA was one of the first engineering companies to develop concrete solutions in the field of networked production - industry 4.0. In the meantime, a variety of megatrends have added their influence. Demographic change, increasing digitisation, increasingly scarce raw materials and, last but not least, ever accelerating climate change are challenges that can be met with the right products. In order to cope with this increasing complexity, DESMA has set out to become a machine building service provider that integrates into its business partners’ processes. To that end, DESMA has launched the initiative #desmatters - see also www.desmatters.biz.
In addition to the machine, DESMA offers its customers a value proposition and range of services aimed at increasing their competitiveness.
A crucial requirement is the maximum transparency and reproducibility of the production processes. These are created by the digital tools of the SmartConnect 4.U product family, automation and process expertise, a comprehensive service offer and the DESMA eco-system for the integration of business processes, the SmartConnect 4.U platform solution.
At K 2019, DESMA will be creating a space on its 400 sqm stand where customers can experience the range of services they offer. In addition, the Fridingers have come up with something very special this year. - Visitors can get ready to be excited!
Set off for new working worlds
D 968.250 ZO BENCHMARK 750 S3 with FlexCell
The industry 4.0 and the associated demand for the traceability of production data are high on the agenda of all manufacturers of elastomer components.
The increasing shortage of qualified operating staff is presenting the processing industry with increasing challenges. DESMA supports businesses with the newly developed FlexCell. It facilitates the use of standardised injection moulding machines and the integration of the entire article-related process automation into autonomous units that can be flexibly and quickly connected to the standard machinery in a modular and application-oriented manner. FlexCell allows plant modification within a very short time. The interfaces have also been standardised so that the system can be demonstrated live in plug & play operation.
Data integration of mixed batches by reading in a barcode in combination with the recognition of the mould and cold runner systems based on the QR coding is provided by products of the SmartScan series and thus enables correct product parameter assignment.
With the E-Drive cold runner system with additionally integrated PressureSense in each cavity, the actual changeover pressure of each nozzle and thus also the process cycle can be documented as well.
With the laser printer, the plant can mark or engrave rubber and silicone articles of any colour with a clearly recognizable ID. The visualisation tool for displaying the recorded production data has been completely revised and now has a newly developed, web-based front-end within the SmartConnect 4.U-ECOSYSTEM.
D 968.250 ZO BENCHMARK 750 S3 with QuickLock
This machine is the first to produce moulded rubber articles with an overmoulded SmartIdent RFID chip. Article gating is executed via a DESMA standard cold runner. Also for the first time, DESMA's latest generation of 2-circuit servo temperature control units EcoSilence+, which respond extremely quickly and accurately thanks to active flow control, will be used. For this, the system requires less energy. When the cold runner system is changed, the cooling media are automatically sucked out so that a dry cold runner can be stored.
The mould can be exchanged within minutes using the QuickLock quick clamping system. Mould clamping is ensured even in the event of a power failure or a complete drop in hydraulic pressure. A mould change with a hot mould will be presented live.
D 969.300 SEALMASTER (S3) with 3500 bar high-pressure injection unit and new PerformanceHydraulics
The bestseller from the DESMA horizontal machine range is now available with a hydraulic performance kit, which will be on display at the stand. Without changing the ServoGear driving power, all movements of the mould carrier and the hydraulic core lifters have been significantly improved. Depending on the motion sequence, cycle time reductions of 2.5 - 5 seconds can be achieved.
The enhanced servo-driven brush modules called ServoBrush are equipped with a powerful external electric drive and have a horizontal axis for freely selectable position adjustment. This allows the wear of the brushes to be easily compensated by automatic infeed. In addition, a spraying device is integrated, which guarantees an optimally reproducible spraying pattern due to the servo-driven brush modules. The brush body can be changed within a very short time with the mould remaining installed and requiring only few tools. The scanner query integrated in the brush head checks for safe article demoulding and thus guarantees an error-free automatic cycle.
This machine will be presented with a ZeroWaste ITM pot for runner-loss free direct injection of articles and a 12-fold sealing mould with different article geometries.
Iso+ heating plates are used to further reduce the energy consumption of this ServoGear machine. The EnergyControl+ system with energy-optimised machine start-up ensures further savings. The integrated load management achieves a significantly reduced peak current intake, which significantly determines the electricity price. In addition, all energy consumption of the individual components, including compressed air consumption, is recorded and allocated. The proven DesCure heating time calculator is also used in this machine.
D 969.100 Z (S3) with FIFO C high-pressure injection unit and PartnerFlexCell
This basic machine with a footprint of less than 4.5 m² is particularly ideal for small series production of precision seals. Mould or mixture can be changed quickly. This is made possible by the FIFO C injection system (100 ccm, 2450 bar) with integrated PlastControl and swing-out extruder unit. If required, the plasticising screw can be quickly removed for inspection or cleaning.
In HTV silicone applications, the material can be exchanged easily and largely without losses thanks to the new CartridgePlus cartridge plug unit.
This system will be presented with a PartnerFlexCell, which is equipped with a collaborating 6-axis robot system and offers three-dimensional scanner protection via a new CE-compliant safety concept. This enables robots, machine and people to work together without mechanical safety guards. The PartnerFlexCell is also designed for easy transfer to other machines. Thus, either pure machine operation or system operation is possible by switching over.
A ZeroWaste ITM system with a mould for the production of small rubber-metal articles is also used on this machine. The metal parts are fed into the mould by the robot.
Fully on trend with the DRC 2030 TBM
DRC 2030 TBM is the DESMA rubber control tool with trend-based machine visualisation. The 24'' multitouch panel in combination with a 2.8 GHZ and 4 GB RAM processor as well as a 64 GB SSD hard disk offers a noticeable added value for the customer: The trend-based display prevents the production of rejects or machine downtime by means of an elaborate threshold value management. Up to 5 Fx rows are freely selectable and programmable. The complete order management can be represented. All documents required for machine operation can be handled digitally. The SetupAssist feature for error-free machine setup has been extended by the mould change guide and the number of screen pages has been reduced by half compared to the previous model.
The DESMA performance programme for service and pre- & post-sales products
Optimised injection moulding with SmartFlow
With SmartFlow, DESMA for the first time offers "in-house" flow simulation calculations for injection moulds or injection moulding processes. The data are simply entered in the user interface, which is identical to the user interface of process visualisation DRC 2030 TBM.
Automation solutions are already simulated three-dimensionally in the project planning phase and realistically on request.
DESMA's own automation team plans, simulates and implements the complete robot animation and robot programming, including integration into machines and associated mould concepts for new plants and retrofits, on a turnkey basis. Data access to all components allows an almost realistic representation of functions from all angles. This also simultaneously generates the robot programme.
By integrating this automation department into our project department, DESMA is able to deliver high-class and meaningful technical plans as early as in the project planning stage.
With the GapAnalyser developed by DESMA, similar article productions can be compared to represent a theoretically optimal cycle. The DESMA GapAnalyser software then gives clear instructions on how to correct deviations in the individual machine cycles. In practical tests, successful optimisations of approx. 3% were achieved in the sealing area. This means that productivity could be increased by 3% after the causes of the different cycle times had been eliminated. DESMA offers analysis with the GapAnalyser as a service.
Foresight instead of repair - the ServiceCommitmentPackage
The DESMA ServiceCommitmentPackage is meant to increase equipment availability. The Service Commitment Package, individually tailored to customer requirements, defines preventive maintenance operations based on demand, in order to define a spare parts strategy and prevent machine breakdowns in good time. All necessary jobs, including hydraulic oil management, HydroClean, and preventive maintenance can be individually integrated with SmartPredict to achieve the highest possible availability effect.
SmartTrace - article traceability down to the individual cavity
DESMA will present several new options for reliable article identification, allowing allocation to the production data even after many years. The integration into the customer’s ERP environment is supported by DESMA with a customised service.
The SmartConnect 4.U-ECOSYSTEM
What was presented internationally three years ago with a roadshow on the subject of industry 4.0 and machine networking has now evolved into a platform which, in addition to pure machine networking, reflects the entire business relationship and will also be available to customers, DESMA and other business partners as an internal communication and knowledge platform.
All SmartConnect 4.U products that have been developed further in the meantime are now integrated and also available as a total of 12 individual SmartConnect 4.U products.
Hydraulic oil management HydroClean
Hydraulic oil change after a specified time or based on actual condition? Even better: The filling lasts the whole machine life. DESMA offers optional and retrofit packages for oil sensors, additional filter systems or complete oil reprocessing on the machine as a service and a new product.
Retrofit kit PerformanceHydraulics
For the D 969.300 Z Sealmaster S3, DESMA offers the PerformanceHydraulics retrofit kit, which facilitates savings of up to 3 seconds depending on the cycle sequence.
The SmartWall – well-protected machine technology
With the optional and retrofit SmartWall equipment, all Ethernet-equipped control components of the machine can be inexpensively brought together in the machine network within the control cabinet and protected against unauthorised external intervention. In addition, this allows remote maintenance access for malfunction diagnosis, troubleshooting and production increase by the DESMA service team if an Internet connection to the machine is available.
The DESMA mould making and cold runner expertise
In addition to specialty mould making, DESMA also offers technologies optimising gating, flash, quality and cycle via the FlowControl, E-Drive, and open or closed cold runner systems, and conventional or ZeroWaste ITM systems. In combination with the extensive application technology services, DESMA can significantly increase the resource efficiency of the user. The potential is demonstrated on the WorkBench, DESMA's own mould and cold runner assembly station.
DESMAcademy and SmartTraining
The DESMAcademy teaches machine and process engineering at the DESMA training centre and in the field of application. DESMA has increased the number of instructors to three and will provide the DESMAcademy with a new home. SmartTraining complements the distance learning programme - feel free to try it out! The didactic approach and the topics of the training programme are perfectly coordinated to teach knowledge and skills ranging from material science to article quality, and from mould handling and injection moulding to the complete automation programme with digitisation applications.
DESMA is looking forward to welcoming you at K 2019 from 16th to 23 October in hall 16 at stand F56.
INDIAN RUBBER EXPO 2019
The IRE in Mumbai is the perfect forum to present our latest machine and cold runner technologies as well as our SmartConnect4.U portfolio to the Indian rubber industry. In addition, General Sales Manager Harald Schmid gave an exclusive lecture on DESMA cold runner technology. This was an opportunity to exchange valuable knowledge and networking of experts.
Many thanks also to our Indian colleagues! We couldn't be better positioned than with this team!
OUR REVIEW OF THE YEAR 2018
Dear Business Partners,
United we stand! In the figurative sense this means: Unity makes us strong. This motto is written on the state flag of Kentucky, where our US North American-subsidiary (DESMA USA, Inc.) is located in Hebron. It is derived from the Anglo-Saxon saying “United we stand, divided we fall”.
How true and symbolic this saying is regarding the past year in industry, society and politics. In fact, the contrast between the economic success achieved and the unrest in society and politics on a global level was most evident in 2018.
At DESMA, our sustainable success rests in our everyday business practices. Clear communication, solution-oriented discussions and shared goals create good cooperation between our customers, employees, suppliers and shareholders. Interaction between DESMA locations around the globe and amongst our employees is at an all-time high. This global cooperation, expressed as a non-copyable original - was outlined in this year’s DESMA RECORDS Magazine with the core subject entitled ONE TEAM.
We are very pleased to report that our hard work and dedication led us to conclude the most successful year in our company’s history. While we are proud of actions in 2018, our results do not make us complacent, but provide both impetus and obligation to keep the ball rolling. Together we will continue to secure and expand our customers’ productivity through our contribution of engineering and technology. So please, keep on challenging us!
Looking forward, DESMA foresees societal challenges to include megatrends of mobility change and demographic development. We also envision increasing demands on resource efficiency and anticipate rapid advancements in the field of automation and digitization. With such trends in mind and with an eye towards the future, we would like to announce a € 15 million investment, beginning in 2019 at various DESMA facilities around the globe. These investments will improve product development, increase productivity, expand upon training programs and improve our operational systems. These investments are our commitment to the future. These investments allow us to embrace the phrase united we stand as unity indeed makes us strong.
With the holiday season upon us, we would like to thank you for the good and successful cooperation in 2018. Thank you for the trust that you have placed in DESMA. We wish everyone good health, good luck and sustainable success for 2019!
On behalf of team
Martin Schürmann Dr. Harald Zebedin
DESMA IS UNIQUE FOR ME!
Interview with Markus Braun, Head of IT , celebrates 10th anniversary at DESMA:
How did you come across DESMA?
Markus Braun: "At a very early age, I was interested in everything revolving around computers so that it was always evident for me to make the hobby a profession.
Many internships provided insights into very different IT worlds – from the typical 'hardware forge' to software enterprises.
While ambling through the Education Fair in Tuttlingen in 2008, I became aware of DESMA in Fridingen and actively informed myself about the company and the IT job profiles there.
I was fascinated by getting to know the information technology at a mechanical engineering company and applied for an internship at DESMA. As a response to this application, I was made aware of a recently advertised apprenticeship position for business informatics. I spontaneously decided to prefer this training at DESMA to studies actually aimed at."
What has been the most impressive experience so far?
Markus Braun: "Apart from many successful projects I have been able to implement so far, I especially remember other interpersonal experiences, such as the trust placed in me when being entrusted with an executive position, the moments I learnt a lot within a very interesting training program, many precious pieces of advice from experienced DESMA employees on the development of a DESMA junior executive, the strong support I received during my studies, and particularly getting to know the people in the enterprise who have made DESMA so unique and interesting for me.
There is one special event which I like to recall. In 2015, DESMA celebrated the big 50-year anniversary. It was impressive to see how much pride and enthusiasm we took to prepare the celebration jointly, how we celebrated it and how the DNA of DESMA was presented."
What makes DESMA special for you?
Markus Braun: "To me DESMA is a modern and flexible company looking incessantly at the latest innovations and constructive changes – not only in terms of the product, but also in process management and organization.
This involves for my responsibility a daily challenge which preserves the thrill not to lose the pleasure in working thanks to having the chance to actively shape the process of change.
Those 10 years at DESMA also showed me that it has been the tireless dedication and the high flexibility of the DESMA employees which have made this corporate culture possible at all - because the human aspect has not been forgotten!"
How did you experience the development of the company?
Markus Braun: "My vocational training started 2008, the time of crisis of the entire global capital market and apparently I had caught the worst time for a start - that was at least my thinking. However, it was rather interesting to see and to actively take part in freeing us from the then heavily depressive market situation enabled by DESMA's continuous strong focus on innovation & growth. Since then, we have witnessed a very positive market development from which DESMA has emerged stronger than ever before and has continued to expand its claim as the market and technology leader in the niche market of elastomer injection moulding machines especially by launching at an early stage many digital software products as technical innovation boosters of the digital age."
What do you regard as the most important challenges for the future?
Markus Braun: "With the worldwide introduction of the SAP S/4HANA ERP system, DESMA is facing the major IT project in the company's history which I will actively attend. I am looking forward to this big challenge and to a continued interesting, exciting and instructive time at DESMA."