Issue 01/16

PEFC / 04 - 31- 0830

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Hard-wired for success. Sauber Motorsport AG 18

Searching for open doors. JP Funkenerosive Bearbeitung 6

If you want high quality, you need high-tech production. K-L Präzision Falk Lange GmbH 12

MITSUBISHI ELECTRIC EUROPE B.V. Mechatronics Machinery / Mitsubishi-Electric-Platz 1 / 40882 Ratingen / Germany The smart magazine for users. Tel +49 (0) 2102 486-6120 / Fax +49 (0) 2102 486-7090 / [email protected] / www.mitsubishi-edm.de Profile 18 Hard-wired for success. 6 Searching for open doors. 12 If you want high quality, Sauber Motorsport AG JP Funkenerosive Bearbeitung you need high-tech production. K-L Präzision Falk Lange GmbH

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Published by Mitsubishi Electric Europe B.V German Branch Contents Mechatronics Machinery 4 Editorial 34 The fascinating world of Mitsubishi Electric. Mitsubishi-Electric-Platz 1 40882 Ratingen · Germany Mitsubishi Electric 5 News Tel +49 (0) 2102 486-6120 40 Big attraction. Visitors flocked to the official opening. Fax +49 (0) 2102 486-7090 [email protected] 6 Searching for open doors. Mitsubishi Electric www.mitsubishi-edm.de JP Funkenerosive Bearbeitung Copyright 46 Service & support – holiday for your EDM. Mitsubishi Electric Europe B.V. 11 Back issues/change of address Mitsubishi Electric Editorial board Hans-Jürgen Pelzers, 12 If you want high quality, you need high-tech production. 48 Mysterious Japan – on its way into the future. Stephan Barg, K-L Präzision Falk Lange Japan Special alphadialog public relations

Design and layout 18 Hard-wired for success. 52 Three in one go. High precision from the gemstone town. City Update Ltd., Düsseldorf Sauber Motorsport Wolfgang Loch No responsibility is taken for the accuracy of the technical 28 Punching above its weight. Wire-cutting stamping tools. 58 User horoscope data and information in articles. MPE Garry

Contents

Exciting reports from the world of wire EDM. 5 Profile01/16 Profile01/16 6 Editorial News

Hans-Jürgen Pelzers

Mitsubishi Electric delivers railcar air-­ Everything on a single site – Mitsubishi Electric conditioning systems for the Rhine-Ruhr opens its new German headquarters Express network in Germany On 4 March 2016, Mitsubishi Electric ­officially Mitsubishi Electric has awarded its first contract opened its new German headquarters in with Siemens AG for railcar air-conditioning sys- Ratingen with a ceremony that included many tems, which will be used in Desiro High Capacity traditional Japanese elements. Its more than Coming together is a beginning; keeping railcars on the Rhine-Ruhr express (RRX) train 16,000 m² of office space will accommodate network that connects cities and provinces in up to 750 employees. The investment also together is progress; working together Germany’s North Rhine-Westphalia region. marks the launch of a new exhibition concept Mitsubishi Electric will deliver 328 air-condition- “The World of Mitsubishi Electric”. is success. ing systems (82 trainsets totalling 164 cars). Continued on page 34.

Henry Ford

Milliseconds with maximum means – 10 years But high performance is by no means confined of the Sauber partnership to Formula One – at the new German head- quarters in Ratingen near Düsseldorf the unusual Nowhere is more effort put into making mil- is on show in the World of Mitsubishi Electric lisecond improvements per lap than in Formula (page 34). And for anyone who didn’t have the One. The Sauber Formula One team produces chance to visit us on our Open Day, we have over 20,000 parts on Mitsubishi Electric EDM summarised the day’s highlights (page 40). machines per year in order to make this all- New low-height cassette for European ceiling Mitsubishi Electric is official advertising important millisecond difference. Meeting these Plenty of progress for 2016, but one thing re- grid ­partner of “ZOOM Erlebniswelt” high expectations means adopting exceptional mains unchanged: Mitsubishi Electric is a partner production methods: workpieces filled with liquid you can count on – not only when it matters. The City Multi VRF series from Mitsubishi Electric Mitsubishi Electric is official advertising partner metal, ingenious auxiliary configurations and is now compatible with suspended ceilings only of “ZOOM Erlebniswelt” in Gelsenkirchen. At much more (see page 18). 245 mm deep, thanks to its European ceiling grid “ZOOM Erlebniswelt” you can travel around the cassettes. Only 208 mm in height and 625 mm world through the Alaskan, African and Asian wide and deep, the new European grid cassette worlds of adventure on a ­single day. Experience fits in all commonly used system grid cassette animals, landscapes and ­attractions. ceilings. Comparable products on the market with a height of some 300 mm need noticeably more Hans-Jürgen Pelzers space in the ceiling recess. from the Technology Centre in Ratingen

News

Enjoy your read of this issue! 7 Profile01/16 Profile01/16 8

Founded in 1999 Die-sinking/wire-cutting jobshop

JP Funkenerosive Bearbeitung Searching for open doors.

When jobs have to be accomplished quickly and flexibly, Jürgen Pirgl is ­always at the ready. His trusty sidekick is his Mitsubishi Electric machine of the MV Series on which he can always rely.

“When one door closes, another unit joined the firm’s machine park ing and then go to work. And in the one opens,” or so the German at Christmas last year. The saying evening after work, I’d finish off ­say­ing goes. Anyone opening the also applies admittedly in another the job,” the jobshop owner recalls. door to JP Funkenerosion and respect. Because Pirgl is always on After about a year and a half, in ­entering the production shop can- the lookout for new business chal- which he was busy almost around not overlook the pride and joy of lenges – and for new doors to open. the clock, Pirgl took the plunge in the one-man business in Erligheim: setting up his own business. a new MV2400R. The wire-cutting About 17 years ago, Pirgl started machine from Mitsubishi Electric out electric discharge machining He then bought his first wire-cut- takes centre stage by the large as a side line in a rented workshop. ting machine a year later, although windows of the company building, “I’d clamp workpieces on a die- this wasn’t planned at all. “My

The automatic wire threader rethreads the resplendent in the bright light. The sinking machine in the early morn- original idea was to concentrate on wire trouble-free even after breakage in a 0.5 mm kerf.

JP Funkenerosive Bearbeitung

The constant search for new challenges. 8 Profile01/16 Profile01/16 9

Electric model. “The truck pulled up expecting his parts to be machined Sudden urgent outside the firm at 8 o’clock in the at short notice by the following day. jobs I still handle at morning, and the new wire-cutting And without compromising on qual- the drop of a hat. machine was ready to operate after ity of course. So I’m always at the the lunch break,” says Pirgl describ- ready as far as new jobs are con- ing the trouble-free delivery and in- cerned,” says Pirgl. stallation of the machine. “The time taken to get used to the new ma- Competitive pricing chine was minimal, as I was already As a subcontractor, the cost-effec- Electric MV2400R. “I urgently familiar with the user interfaces tive price per part is the decisive needed a high-performance machine of the Mitsubishi machines. So I factor for survival on the market. particularly for larger workpieces. was able to get straight down to Pirgl therefore needs a machine A pleasant side-effect of any new work.” So the seamless resumption that operates economically. In view investment is that it gives me a of normal business was at no time of this, the low wire consumption burst of new enthusiasm for my at risk. “For a successful jobshop, of the new MV Series has already daily work,” Pirgl explains. The speed and flexibility are absolutely had a positive impact in the brief new machine was bought in part essential. You can never rule out a time since commissioning. “I reckon exchange for an older Mitsubishi customer ringing up on a Friday and a single wire spool now lasts about

A perfect fit – two components with gearing

“For a successful jobshop, speed and flexibility are absolutely essential.” – Jürgen Pirgl

die ­sinking. But because custom- tor racing were concerned. “These of them are still located in the im- ers kept on inquiring about special customers were often very de- mediate surroundings. Wire-cutting gearing, I seized the opportunity manding, because they expected accounts for about 70 per cent of and bought a used Mitsubishi SX their components to be machined the order volume. The jobs usually machine. This meant I could then practically overnight,” says Pirgl. involve parts made of aluminium, handle these jobs as well,” Pirgl Although these customers are no copper, brass, steel or titanium, explains. longer his regulars, the business 0.5 to 300 mm thick, up to a size of owner managed to gather a lot of 700 mm. Pirgl is extremely flexible Over the years, he’s made steady valuable experience during this and not so selective when it comes progress and the company has suc- period from which he still benefits to taking on new orders. For his cessfully established itself on the today. “Sudden urgent jobs I still motto is: “If my machine can do it, market. The bulk of his work was handle at the drop of a hat. And my I offer it”. originally from customers from the customers are very appreciative of local area of Heilbronn and Stuttgart this,” he adds with a smile. Always at the ready for the and came from a variety of indus- ­customer tries. In the initial years, things were Today the company serves many The used machine from Pirgl’s ini- sometimes hectic, particularly when machine manufacturers and tial years has long gone. Today he jobs for companies engaged in mo- ­component suppliers, and most works at the modern Mitsubishi

JP Funkenerosive Bearbeitung

Successfully established on the market – step by step. 10 Profile01/16

Free know-how for you to back order – as long as stocks last. Profile back issues FOR FREE

Pirgl appreciates the rapid familiarisation and the accustomed user interfaces. Pirgl handles urgent jobs overnight.

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r o The Art of P Issue Economy 02/14 · December

PEFC / 04 - 31- 0830 The Art of Economy Pirgl reporting his experience. The racy, dependability and economy. necessary yet on the new machine. Issue 01 · July 2014 Pro l e jobber has also come to ­appreciate And competitively pricing. However, Pirgl has no doubts that Advertise your Profile! PEFC / 0

4 - 31- 0830

Would you and your com- The Art of Economy pany like to be in the06 next

y 5 edition? Poetr /1 the other innovative features of the Mitsubishi Electric service will 01 in motion l e DMF Werkzeugbau Advertise your Profile! Pro Then write to us!

18 Mitsubishi Electric Europe B.V. Would you and your companyAn innovation the MV2400R. The automatic wire quickly respond should the need German Branch At the end of the guru shares his Dependability counts Mechatronics Machinery Profile! toolmakinglike chain to be in the next edition? Advertise your Gothaer Strasse 8 Future-TEC knowledge. Interview 40880 Ratingen · Germany Prof. Hermann Simon Would you and your company Tel +49 . 2102 . 486 6120 Then write to us! like to be in the next edition? Fax +49 . 2102 . 486 7090 6 52 The Art of Economy Then write to us! edm.sales @ meg.mee.com Sights set on the future. Issue 01/ www.mitsubishi-edm.de World of sport Interview 15 threader, which rethreads the wire In Pirgl’s opinion, the competitive arise and send a technician round · May Sponsor of Offi cial Salomon SA Fraunhofer ICT-IMM

26 A useful addition. Wire EDM in series production. trouble-free even after breakage in pressure has increased from year to swiftly. Huber Präzisionsmechanik AG

- 31- 0830 PEFC / 04 38 MITSUBISHI ELECTRIC EUROPE B.V. Mechatronics Machinery / Gothaer Str. 8 / 40880 Ratingen / Germany / Tel +49 (0) 2102 486-6120 / Fax +49 (0) 2102 486-7090 [email protected] / www.mitsubishi-edm.de Back issues Sustainable a 0.5 mm kerf, operates without a year since he started his ­business. The smart magazine for userssuccess: eco-friendly production, MITSUBISHI ELECTRIC EUROPE B.V. Pro reduced costs. Mechatronics Machinery / Gothaer Str. 8 / 40880 Ratingen / Germany / Tel +49 (0) 2102 486-6120 / Fax +49 (0) 2102 486-7090 [email protected] / www.mitsubishi-edm.de Mitsubishi Electric el

The perfect showcase for generating business. hitch. “You usually don’t even notice “It used to be easier to plan ­orders For the go-it-alone businessman, Moulding Expo Stuttgart 12

Where there’s a will, there’s a way. a wire breakage. All you see is a that would arrive in a steady vol- one thing is already certain – that and change of address. Rainer Lortz CNC-Technik 30

54 message on the display,” says Pirgl ume. Today you have to react much he will stay true to investment in The smart magazine for users. Pro who wouldn’t want to do without faster and reckon with greater fluc- machines of the Mitsubishi Electric el this function. tuations in the order volume.” Pirgl brand. “Experience saves time” is regards this as a challenge and how he puts it. Another important factor in subcon- adapts flexibly to changing condi- tracting is machining speed. Time tions. It is therefore all the more is a precious resource, and staying important for him to have a machine Simply cut out and send off the coupon! competitive means using it spar- for his daily work that he can rely on Back issues ingly. Pirgl is therefore very happy 100 per cent. Yes, I’d like to order back issues of the following Profilemagazines (please enter desired number): with the markedly enhanced per- formance of his new system. Most In this connection, he has words 01/2014 02/2014 01/2015 02/2015 Current issue important of all is the machine’s of praise for Mitsubishi Electric’s dependability. “What use is high after-sales service. Pirgl has oc- Address /Change of address Yes, I would like Mitsubishi Electric to keep me cutting speed if the machine breaks casionally carried out minor repairs ­informed of its special offers and campaigns by email. down in the middle of the night?” himself. “It just took a phone call, Company says Pirgl. In his view, the MV2400R and the replacement parts arrived www.jp-erodieren.de Surname First name Date, signature

No., road Note: Your data will not be passed on to any third parties except companies involved in the process­ Post code Town, country ing of your order. You can terminate the storage of your personal data at any time by simply sending a fax to +49 . 2102 . 486 7090 Email address Phone

Taking account of fluctuations in order volumes. MITSUBISHI ELECTRIC EUROPE B.V. / Mechatronics Machinery / Order by fax Profile Reader Service / Mitsubishi-Electric-Platz 1 / 40882 Ratingen / Germany +49 . 2102 . 486 7090 12 Profile01/16 Profile01/16 13

Everything from tool- and Founded in 9 ­mouldmaking and precision part 1998 employees ­fabrication to small machine manufacture­

With an advanced high-tech machine park, Falk Lange has made K-L Präzision a trendsetter in the region. Its demanding customers benefit from the extraordinary quality of its machined products. K-L Präzision Falk Lange GmbH

In picturesque Nideggen, Lange inaugurated his new The new building with its light-flooded production shop production shop in 2014. The Eifel National Park and is working to high capacity only a year after the firm the High Fens are within easy reach. “Here we’ve got moved in. Some 900 m² of space is available for produc- If you want high quality, everything we value,” says Lange summing up, “– a tion and 100 m² each for offices and staff rooms. central location between Cologne and Aachen, a high- Armed with a wealth of expertise, a pronounced commit- you need high-tech production. speed Internet connection and an idyllic landscape ment to quality and, above all, a clear understanding as well.” of the needs of his customers, Lange took the leap in

K-LWerkzeugbau Präzision Falk Trentzsch Lange GmbH

A pronounced commitment to quality. 14 Profile01/16 Profile01/16 15

demanded standard. For medical technology applica- says Lutz Roger Neuendorf, the responsible Sales tions in the USA, we’ve produced injection moulds, Manager, outlining the strategy of the leading EDM One of our strengths is for example, and performed the die sinking with our manufacturer. Service management has therefore been ­undoubtedly the business’s high immaculately cut electrodes. The customer was so working even more closely with sales for some time ­manufacturing depth. impressed by the outstanding quality that he awarded now and has steadily adjusted manpower to the grow- us follow-up orders,” says an enthusiastic Lange. ing capacities of the sold units. In addition, Mitsubishi Mitsubishi Electric makes it easy for users to integrate Electric mans its service hotline during the week until rotary and articulation axes. The controls of the more 8 pm and on Saturday even until 4 pm. “The better the recent EDMs are designed for the integration of extra service, the more satisfied the customer. And satisfied axes and also make it possible to control additional customers are loyal customers, as one can see from axes simultaneously. K-L Präzision,” Neuendorf affirms, bringing his construc- tive consultation with the customer to an end with a Dependable and long-term cooperation friendly smile. Before a workpiece goes to the measuring room, it has to withstand close Lange gathered his first experience with the machines ­scrutiny from Viktor Voth. from Mitsubishi Electric back in 1986, many years be- fore going it alone. “My workmate, who at the time was responsible for wire-cutting, left the firm at short notice. So I had to stand in for him and was really thrown into the deep end. But it didn’t take long for me to feel at setting up his own business in 1998. Today, a total of machines, but also machining centres, surface and home on the DWC 90,” Lange recalls, laughing. Today, www.k-l-praezision.de nine employees work for his firm, all of them specialists cylindrical grinders, lathes and, last but not least, a total of nine machines from Mitsubishi Electric are in who have a complete mastery of their respective trades ­professional measuring equipment. With its ambitious operation in Nideggen – four die-sinking and five wire- and are able to machine with micrometre precision. One aspirations, the company has acquired a unique posi- cutting machines. When setting up his own business, of them is Felix Lange, the founder’s son. The tool me- tion for itself in the region. “Being just one of the crowd Lange opted exclusively for EDMs from the Japanese chanic by training is ensuring second-generation con- is not my thing,” is how Lange explains his philosophy. manufacturer. Two factors were critical for this deci- tinuity in the family business. “One of our strengths is “We may not always be the cheapest operator, but our sion: first, their innovative technology; and, second, the undoubtedly the business’s high manufacturing depth,” customers acknowledge the quality of our work and excellent service and support. “I’ve always studied Lange explains. “With the exception of hardening, we have realised that our strength lies in the dependable what’s on the market thoroughly. Technological advances perform all the jobs on the premises and can therefore execution of challenging tasks,” he adds. like the Tubular Shaft Motor, automatic wire thread- respond very quickly and flexibly to customer re- ing and the new generator technology are outstanding quests.” On the basis of his many years of experience, The personal touch features. What counts for me ultimately, however, is the Falk Lange can also realistically assess the feasibility Lange works alongside his team in production at the overall package of technology, service and price. And of more extravagant customer requests. “If a customer machines. He attaches great importance to personal Mitsubishi has always had the best offer so far,” says comes along with his drawings and instructions, we relationships with his employees for he knows that high Lange justifying his choice. consult with him in detail and conscientiously examine employee satisfaction has a positive impact on qual- the required work steps in advance,” Lange reports. ity and productivity. He is not only ready to help his staff Satisfied customers are loyal customers “When we then confirm the job and give our okay, the with his technical expertise, but also always has an ear A particular strength of Mitsubishi Electric is its excel- customer can rely 100 per cent on getting precisely for organisational and even personal concerns. lent after-sales service. “Should a problem ever arise on the tool he’s ordered.” a machine, it’s quickly solved. We’ve never had to wait A perfect cut for an answer longer than an hour. This is something I Always one step ahead When cutting special electrodes, the five standard axes can always rely on,” says the business owner. “By con- Lange has always been fascinated by high tech and of the Mitsubishi Electric EDMs are not always suf- trast, I find annoying the tendency of other manufactur­ aspires to always be one step ahead of the competi- ficient. This is when a rotary axis comes into play at ers to respond sluggishly. Sometimes there’s even a tion. So it’s hardly surprising that his machines always K-L Präzision. “Of course it’s also possible to cut risk of a whole working day being wasted unproduc- keep pace with technological progress. The advanced these special electrodes in segments without an addi- tively.” “We’ve come to appreciate that technical sup- machine park of K-L Präzision is in every respect state- tional axis,” Lange admits. “But that’s time-consum­ port is increasingly becoming a make-or-break factor. With its light-flooded new building, Falk Lange has paved the way for his of-the-art and comprises not only electric discharge ing and the surface quality falls a long way short of the This is why we have redoubled our efforts in this area,” ­business’s successful future.

K-LWerkzeugbau Präzision Falk Trentzsch Lange GmbH

The modern machine park is state-of-the-art. 16 Profile01/16 Profile01/16 17

The success story: Lange – Mitsubishi Electric Interview

Falk Lange Managing Director and owner

Moving into the new shop First Second EA8 and and first FX20K FA20Advance second FA20 Advance Third EA8 Can you explain in a sentence what your What was your biggest business success? 1999 2002 2007 2008 2009 2010 2010 2012 2014 ­company does? Building up K-L Präzision Falk Lange with sup- We’re a company that operates on the principle port from my family and my reliable workforce. First FX10K First EA8 First EA12V First FA30V New shop wire-cutting machine die-sinking machine first MV2400R of “A rolling stone gathers no moss”. first NA1200 What attributes do you value most in others? What’s your source of motivation? Hard work and honesty. The principle of never resting on our laurels, but always staying one step ahead.

Where do you see your company in five years’ Lutz-Roger Neuendorf, responsible Sales Manager: ­expertise. Our contribution to this long-standing time? “I’ve been serving Mr Lange since he started partnership is our support for K-L Präzision with As a high-tech company that sets trends in the his own business and am full of respect for how suitable equipment and technologies in the EDM region. K-L Präzision has developed. This remarkable sector. I’ve always found this extremely ­harmonious ­company has become established on a firm foun- business relationship to be down-to-earth and dation and with a lot of hard work and technical ­professional and also enjoyable.”

Company profile K-L Präzision Falk Lange GmbH

K-L Präzision Falk Lange GmbH Managing Director and owner Employees Grünland 4 Falk Lange 9 52385 Nideggen-Schmidt, Germany Tel +49 (0) 2474 99779-0 Core business Founded in Fax +49 (0) 2474 99779-29 Everything from tool- and mouldmaking 1998 [email protected] and precision part fabrication to small www.k-l-praezision.de machine manufacture

K-LWerkzeugbau Präzision Falk Trentzsch Lange GmbH

Background information on the precision specialists. 18 Profile01/16 Profile01/16 19

Speed is all-important in Formula One – and the same applies to the ­production Founded in of the vehicle components. The Swiss Sauber F1 Team has been using EDM Some 350 Motor racing – Formula One 1970 employees systems from Mitsubishi Electric for over ten years. These high-tech units ma- chine even the most intricate workpieces quickly, accurately and in top quality – and have therefore become absolutely ­indispensable for Sauber.

Everything is meticulously tidy in ­partnership has become a corner- cooperation: Mitsubishi Electric Alexander Simai’s workshop. Like a stone of the production strategy of benefits in the marketplace and we jeweller presenting his finest work, the Swiss racing team, as efficient benefit in production,” says Axel he has neatly arrayed his latest pro- spark erosion facilitates machining Kruse, Operations Director of the duction items on his work bench: feats that would be out of the ques- Sauber F1 Team. switches, screws, locking rings and tion with conventional turning and chassis components. “These one- milling methods. Components for Stalwart in turbulent times off items are employed in various the ­suspension, cockpit, steering The NA2400 and MV1200R wire- places on our Sauber C35 Ferrari,” column or brake pedals have to be cutters and the EA12V die-sinker says Simai, proudly smiling as he produced quickly, with micrometre are the key items of production picks up his most recent item, a precision and in superlative quality equipment in Hinwil. The mechanics titanium part for the wheel suspen- so that they can bring to the circuit use the high-tech systems around sion. “Machining this is very com- a vehicle that can compete speed- the clock and for almost all purposes plicated. You’re given a 3D model and safety-wise. Mitsubishi Electric – for the preliminary machining of and you have to work out how to machines satisfy these requirements. safety-relevant parts and for the fin­ machine the component.” So far, “With Mitsubishi Electric’s help, we ishing of milled parts. Of the total Simai, whom his colleagues in the have reorganised our production pro- of roughly 80,000 workpieces that Swiss Sauber Formula One team cess so that we are at an advantage they machine each year, 25,000 to ­approvingly call “Erosion Man”, has in terms of speed, flexibility and also 30,000 come off the EDMs. At the managed to solve every problem. costs. Both companies profit from start of cooperation with Mitsubishi But the requirements in top-level

motor racing are exceptionally 2016 Sauber F1 Team steering wheel model ­exacting. “You may get the design data for a component on a Friday evening, and it has to be out on the race circuit the next day. So you have to give everything you’ve got Sauber Motorsport AG and be creative and quick at the same time.”

Innovative EDMs from Mitsubishi Hard-wired Electric help Simai to master his challenges. At its workshop in Hinwil near Zurich, the Sauber F1 team for success. has been using high-tech instal- lations from the world market leader for over ten years now. This

Sauber Motorsport AG

Extreme requirements in top-level motor racing. 20 Profile01/16 Profile01/16 21

Electric in 2005, the workshop F1 team with its drivers Felipe Nasr couldn’t have imagined how impor­ and Marcus Ericsson achieved tant this technology would become a commendable 8th position in the for them. “We started off with wire- Constructors’ World Championship. cutting and at first only integrated And despite the fact that the abrupt certain steps in the existing pro- departure of majority owner BMW cess,” says Sauber Production from Formula One in the summer Manager Ernst Keller. Today, they of 2009 severely shook the Swiss rely wholeheartedly on spark ero- team. Nevertheless, team founder sion. “It’s become absolutely essen- Peter Sauber, who bought back tial for us. Without this technology, his baby after the BMW pull-out, Auxiliary configuration for a 360° cut Connection for carbon rods Steering wheel adjusting knob the processes that we’ve adopted got Sauber back on course. This Entrance door to the Sauber EDM department today would hardly be feasible.” was possible also because the team of motor racing’s Premier League could continue to bank on the in- The effectiveness of the Sauber and also made a name for itself as novative capability of important things about staunch partners like specialised firms have set up shop or other persons. Process security approach is indicated by the race a talent factory. In the battle for technology partners like Mitsubishi Mitsubishi Electric. We can rely on in and around Zurich. What’s more, is one of our primary objectives,” team’s consistently good perfor- the World Championship, drivers Electric. Sauber’s engineers have them to continue to refine their tech- the race teams traditionally keep the says Kruse. Precisely because of the mance over the years. Although like Nick Heidfeld, Robert Kubica, never been short of high-tech nology that we benefit from to such number of suppliers small for rea- need for ample reserves of safety, the team has never bagged the Kamui Kobayashi and Sergio Perez components for the racing cars an extent,” says Kruse. sons of quality and safety. Formula Sauber initiated business relations big titles like Ferrari or Mercedes, it have regularly picked up points. or for the company’s own wind One is a high-risk sport in which with Mitsubishi Electric in 2005, as has established itself in the middle And in the 2015 season, the Sauber tunnel. “That’s one of the great Safety first drivers and the people around them the company has always had a fine Even if Mitsubishi Electric has be- have to be protected. And this is reputation for EDM and industrial come a permanent fixture at Sauber why the teams want to exercise as automation. today – getting one’s foot in the much control as possible over their door with a motor racing team is any­ value generation. Sauber is no ex- Easy to tool Ernst Keller, Production Manager, and Axel Kruse, Operations Director, with EDM-machined elements of the current Formula One vehicle thing but easy for an equipment ception: “Our philosophy is to have Alexander Simai can no longer supplier. The machine manufactur­ on our premises all the components imagine his workplace without ing competition is particularly that, in the event of a defect, might Mitsubishi Electric technology strong in Switzerland, and many result in harm to the driver, spectators ­either. “It is spot-on, quick, easy to

That’s one of the great things about staunch ­partners like Mitsubishi Electric. We can rely on them to continue to refine their technology that we benefit from to such an extent.

Axel Kruse Operations Director

Sauber Motorsport AG

Wire-cutting – an essential technology. 22 Profile01/16 Profile01/16 23 operate, maintenance-friendly and event of wire breakage, the machine “The machine runs absolutely Company profile Sauber Motorsport AG robust and produces ­outstanding re­ rethreads the cutting wire right at smoothly.” The ease of operation of sults even in poor conditions,” says the breakage point – in the kerf and the Mitsubishi Electric technology the skilled mouldmaker listing without the dielectric having to be also goes well with Sauber’s speed Sauber Motorsport AG Managing Director Employees the ad­vantages of the machines, fully drained off. “This saves time strategy. According to Production Wildbachstrasse 9 Peter Sauber some 350 before turning to the MV1200R and permits unmanned operation Manager Keller, it is important for 8340 Hinwil, Switzerland whose per­formance he is particu- at night, even for the processing operators to be able to work at new Tel +41 44 937 90-00 Core business Founded in larly impressed by. “With the in- of components that tend to warp machines productively without tak- Fax +41 44 937 90-01 Motor racing – Formula One 1970 stalled zero-point clamping system I during machining.” The mechanics ing long to get used to them. “In our [email protected] can signifi­cantly reduce tooling time in Hinwil are happy to exploit this business, speed is of the essence. www.sauberf1team.com and thus improve productivity.” feature. “We set up vehicle compo- Our processes have to fall into place With the MV-R it’s possible to fin- nents before leaving work and let straight off. With Mitsubishi Electric, ish the job with fewer recuts – and them run on the machine overnight this is possible, as the machines are with exceptional accuracy. “This so that we can finish machining anything but highly complicated to also increases speed.” Furthermore, them the next day,” says Simai. So operate.” In the Sauber workshop, the MV1200R has a “brilliant au- far there haven’t been any problems thanks to hypermodern ­operating tomatic wire threader”. In the rare at all with the automatic threader. and programming equipment,

Die-sinking of titanium wheel suspension

Right before the start of the race

work steps are highly streamlined. fact that the mechanics at Sauber erosion machine? With his wealth of The engineers design the compo- are also responsible for program- expertise and passion, Simai will be nents on a 3D CAD system, and the ming, setting up and operating the facing up to precisely this challenge mechanics, using CAM systems, EDM systems. This ultimately also again tomorrow. then generate the NC cutting pro- creates scope for creativity, which grams and transfer them finally to also plays a big part in the Sauber the machines via a DNC network. process. How can a complex com- Efficiency is also boosted by the ponent be best machined on which www.sauberf1team.com

Sauber Motorsport AG

Slashed set-up times and faster production. 24 Profile01/16 Profile01/16 25 The Sauber chronicle: turbulent years.

FORMEL 1 – THE EARLY YEARS 1993 Flying start. The Finn JJ Lehto achieves 5th place in Sauber’s maiden 1 Formula One race at the South African Grand Prix. 1995 Podium first. Heinz-Harald Frentzen rocks Monza, claiming 3rd place in the Italian Grand Prix. Red Bull and Petronas join the team. 2001 Sound finances at last. Sauber enters into partnership with the Credit Suisse bank, achieves 4th place in the Constructors’ World Championship and builds its own wind tunnel.

THE BMW-SAUBER ERA 2005 Flying a new flag. BMW takes a majority share in Sauber. The new partnership with Mitsubishi Electric injects extra speed into production. 2008 Year of glory. The team grows to 400 employees. Robert Kubica wins the Canadian Grand Prix ahead of team colleague Nick Heidfeld. Collectively, they make it onto the winner’s podium 11 times, and Sauber comes 3rd in the World Championship with 135 points. 2009 Setback. Only 6th place – and BMW pulls out of Formula One. Every 2 cloud has its silver lining: Peter Sauber buys back his baby.

NEW START IN FORMULA ONE 2010 Back to basics. With 260 employees, Ferrari as the engine supplier and the drivers Kamui Kobayashi and Pedro de la Rosa, Sauber achieves a respectable 8th place in the World Championship. 2012 Comeback. Four top-3 placings, 126 World Championship points and 6th place 3 in the Constructors’ World Championship – the team is back on track for success. 2012 Woman at the helm. Peter Sauber steps down as CEO and hands over to Monisha Kaltenborn, who thus becomes the first female team principal in Formula One. 2013 Fighting spirit. Nico Hülkenberg and Esteban Gutiérrez now race for Sauber and drive the team, despite initial problems, to 7th place with the Sauber C32 Ferrari. 2014 Disenchantment. No World Championship points for the first time. The team struggles with poor performance, inconsistent results and errors by the pit crew and drivers. 2015 Breath of fresh air. The two young drivers Marcus Ericsson and Felipe Nasr get Sauber back on track with a seriously overhauled C34 Ferrari. The final analysis: 36 points and 8th place. 2016 Clear message. Team principal Monisha Kaltenborn calls for greater consistency so that Sauber can re-establish its mid-table position in Formula One. Sauber Motorsport AG

Insights into turbulent motor racing history. 26 Profile01/16 Profile01/16 27

F1 EDM FILM

Benefit from the expertise of the Sauber motor racing specialists, gain “Competition takes place fascinating insights and find out about exclusive EDM tips & tricks in two exciting video reports. Watch now online! not only on the track but also in production.”

Axel Kruse, Operations Director The progressive Sauber Formula the tiniest deviations can decide the next day.” Alexander Simai, One race team has opened its doors between victory and defeat when Machining/EDM: “I have to produce exclusively to PROFILE’s journal- time is measured in thousandths a titanium part that’s eight tenths ists and clearly demonstrated what of a second. Ernst Keller, Production of a millimetre thick. It’s clamped counts in high-precision machin- Manager: “We have to work at high like this in an ITS chuck and pre- ing. The technicians themselves speed. For instance, a problem can roughed. Then I machine the titanium EDM GOES MOVIE! have their say and show with crop up on the race circuit on a with graphite electrodes. After Reduced set-up times and faster production – but how? ­reference to specific examples how Friday. We may then get the de- wire-cutting, the pocket is filled with Fascinating insights and exclusive EDM tips & tricks in two exciting EDM technology is employed on sign data late Friday afternoon liquid metal. This gives the mate- video reports. the F1 vehicles. Extreme precision or evening, and in principle the part rial strength. It has a melting point of Scan the code now and find out in the film: is an absolute necessity – even is expected to be out on the track about 80 °C.” www.mitsubishi-edm.de/sauber-en

JUST SCAN THE CODE AND FIND OUT IN THE FILM.

Sauber Motorsport AG

Two fascinating videos – by experts for experts. 28 Profile01/16 Profile01/16 29

Founded in 90 Development and production of 1974 employees ­progressive tools and connector systems

As a member of the global Binder Group, MPE Garry GmbH in Füssen con- centrates on the development and manufacture of progressive tools and connector systems. So that it can machine the tiniest radii and contours on punches and dies with high surface quality, the Füssen toolmakers place their faith in the quality of wire-cutting machines from Mitsubishi Electric.

MPE Garry GmbH

In 1987, MPE Garry GmbH in Füssen evolved out customers can be found in virtually all branches of in- of Werkzeugbau Lotter GmbH founded in 1974 in dustry, ranging from machine and vehicle manufacture, Punching above its weight. Buching. MPE Garry has been a company of the Binder automation and medical technology to computer engi- Group, a globally active manufacturer of electrical con- neering and building equipment. In addition to designs Wire-cutting stamping tools. nector equipment, since 1991. Using metals and plas- conforming to international standards, the Binder Group tics, the total of six companies of the Binder Group de- produces a multitude of customer-specific variants. At velop, design and produce electrical connectors. Their the Füssen location, roughly 90 employees handle the

MPE Garry GmbH

A multitude of customised variants. 30 Profile01/16 Profile01/16 31

assembly and sale of high-grade connector systems. custom connectors. The required component parts Innovative technologies ensure quality and reliability optimum of functions, features and optional extras for These are used for detachably yet reliably interconnect- are mainly produced from highly alloyed, hardenable Because of its strict insistence on high quality, MPE high speed, accuracy, surface quality, dependability ing rigid and flexible circuit boards with multicore data steels. We assemble the modular tools, run them in Garry has chosen machines from Mitsubishi Electric and efficiency.” Trakies bases his assessment among cables. Precision toolmaking in Füssen is of outstand- and then produce the components for a variety of elec- for wire-cutting. The employees have been familiar other things on the advanced direct drive technology ing importance for the corporate group as a whole. tric connectors in large series,” says Rudolf Trakies, with these wire EDMs for almost 20 years. Only a few with Tubular Shaft Motors. In combination with the lin- About 15 employees here develop, design and fabricate head of toolmaking in Füssen, explaining his team’s months ago, the toolmakers in Füssen sold a 15-year- ear scales on all axes and rapid optical data transmis- high-precision stamping and bending tools. Using work. The toolmakers at MPE Garry also work some- old, trusty FA20 and bought a modern MV2400R to sion, it ensures maximum accuracy at high working these, the company produces a variety of stamped parts times under subcontract for neighbouring production replace it. The specialists at MPE Garry now work with speeds. The latter enables MPE Garry to maintain its in large series from 0.1 to 2 mm thick fine sheet metal firms as well as repairing worn or damaged stamping two wire-cutting and one die-sinking machine from status as a competence centre of the Binder Group, on several fast-running presses. In Füssen and at other tools. As Trakies reports, the fabrication of individual Mitsubishi Electric. With the MV2400R in particular, they as the toolmakers in Füssen have to repeatedly stand locations, these are then assembled with plastic bod- components for progressive tools places special de- can achieve an exceptional combination of high accu- comparison with the global competition. “What counts ies into complete connectors. mands on the production equipment. The tool inserts racy, process security and reliability. Trakies explains: is not only high quality, but also throughput time. Only often have edge lengths of only a few millimetres, and “It goes without saying that we are at pains to keep our those who are fast enough will earn further jobs. In this From metal strip to connector the penetrations in the dies are often only a few tenths production equipment in line with the current state of respect, we see ourselves under a special obligation “As a competence centre of the Binder Group, we of a millimetre wide. Equally, the punches often meas- technology at all times. This is the only way we can stay towards our partners throughout the Binder Group,” in toolmaking at MPE Garry are concerned above all ure only a few millimetres in size and have radii of less true to our philosophy of ‘Reliability, quality and respon- Trakies adds. with stamping and progressive tools for very small than 0.1 mm. “This is why we pay attention to maxi- sibility’. In advance of this investment, we compared pins and flat connectors. We concentrate on ingenious, mum accuracy and high surface quality in production,” the wire-cut EDMs on the market. From our point of view, In addition, Trakies has explicit praise for the special finely detailed tools that we produce for standard and Trakies adds. Mitsubishi Electric alone with its MV2400R offers the functionality of the MV2400R. This refers, for ­example,

Rudolf Trakies, Olaf Burkhardt and Sebastian Wörle (from the left) are in no doubt about having obtained, in the shape of the MV2400R, the best-possible wire-cut From metal strip to intricate connectors: progressive tools made of fine sheet metal productively stamp and bend 3-dimensional components ready for assembly. EDM for their precision toolmaking activities.

MPE Garry GmbH

Maximum precision and superlative surface quality. 32 Profile01/16 Profile01/16 33

to the automatic wire threader. The toolmakers in Füssen mainly work with thin wire 0.2 mm and oc- casionally down to as little as 0.05 mm diameter. This is the only way to cut intricate contours and tiny radii. However, these fine wires have a greater tendency to break. Olaf Burkhardt, programmer and operator of the MV2400R, explains: “The extremely dependable wire threader of the MV2400R is a real godsend. The machine can be relied upon to find the right position in the kerf after wire breakage and safely rethreads the wire without a water jet.” The toolmakers at MPE also achieve maximum accuracy in terms of parallel cuts and vertical wire running in tiny inner and outer radii Sebastian Wörle, programmer and operator of the MV2400R: “Thanks to its Neat and intuitive, the user interface of the new AdvancePlus CNC control by making use of the functions of the V350 generator ­mature and comfortable programming and operating functions, the MV2400R ­enables skilled operators to work productively after only a few days of training. with its Precise Finish Circuit at lower cutting speeds. can be quickly and easily set up and tooled.” Maximum surface quality up to Ra ≤ 0.10 µm is as- sured by the proven DFS fine finishing generator.

Comfortable operation, competent service In ever quicker succession, the toolmakers at MPE rameters in the database.” Thanks to this convenient MV2400R satisfies all the requirements in exemplary question of benefiting from attractive financing terms Garry have to produce progressive tools for customised programming and operating strategy, the toolmaking fashion. Compared to the old, proven wire-cutting EDMs, with the aid of selected subsidies. However, these connectors at short notice. This is why they attach so ­department at MPE Garry was able to work produc- it reduces filter consumption, for example, to about a subsidies are strictly tied to energy savings of at least much importance to simple operation and programming tively at the new MV2400R after only a few days. In third or a quarter, on the basis of experience to date in 25 per cent over the previous production installations. and high availability of their production equipment. the event of uncertainty or the need for support from Füssen. As a result of the optimised generator, wire With the MV2400R, we had no trouble negotiating this Here, again, the MV2400R scores well. Since the tool- the machine manufacturer, Mitsubishi Electric’s after- ­consumption is significantly reduced. Overall, it requires hurdle.” makers were already familiar with the user interface of sales service is always on hand – service that meets up to 30 per cent less energy than comparable wire- the old wire-cutting machine from Mitsubishi Electric, with wholehearted approval. As Trakies confirms, a cutting machines. For Trakies, this is a compelling fac- it only took them a few days to learn the ropes effec- skilled contact is always available within half an hour tor: “When we purchased the MV2400R it was also a www.mpe-connector.de tively on the new machine. “What stands out is Mitsubishi during normal business hours. “He competently sup- Electric’s strategy of cautiously modifying the user plies us all the information we need so that we can get interfaces despite the introduction of futuristic techno­ the wire-cutting machine up and running again without logy. This makes for a smooth transition. Operators delay. And this of course contributes to the high availabil- can build on what they know and trust and quickly learn ity of the MV2400R,” he adds. how to make efficient use of the new functions and ­options,” says Burkhardt in praise of the strategy of the Cutting efficiently while saving energy Company profile MPE Garry GmbH AdvancePlus CNC control. In Füssen, the program- However, the quality and modern technology of the mers mainly write the CNC programs on the external MV2400R are not the only decisive features in its fa- MPE Garry GmbH Managing Director Employees CAM system (PEPS). Via a server and data lines, these vour. As Trakies reports, similarly crucial are its overall Schäfflerstraße 13 Markus Binder, Jörn Bargholz 90 are transferred to the MV2400R, where the operator efficiency, profitability and energy consumption. Once 87629 Füssen, Germany can make minor adjustments. Burkhardt elucidates: again, the current technology from Mitsubishi Electric Tel +49 (0) 8362 9156-0 Core business Founded in “As far as the technology data are concerned, our em- is awarded top marks by the toolmakers at MPE Garry Fax +49 (0) 8362 9156-500 Development and production of 1974 ployees can resort to their experience. However, the in Füssen. “Throughout the group, we are ­committed [email protected] progressive tools and connector new machine technology often permits significantly bet- to reducing energy consumption, upholding energy ef- www.mpe-connector.de systems ter parameters. For these we can resort to Mitsubishi ficiency and using resources sparingly. And this applies Electric’s integrated database. The useful thing is that of course not only to the building services and office we can in turn store our individually optimised pa- wing, but also to production,” Trakies explains. The

MPE Garry GmbH

Standing comparison with the global competition. 34 Profile01/16 Profile01/16 35

Manufacture of electronic equipment, e.g. Founded in EDM systems, laser cutting ­machines, >129,000 CNC controls and drives, industrial 1921 employees ­robots, air conditioners, semiconductor ­technology and much more besides.

Mitsubishi Electric The fascinating world of Mitsubishi Electric.

Imagine someone cutting a slice out of the Earth’s crust and unrolling it ­before your eyes. Well, precisely this idea has been realised in the new product ­exhibition “The World of Mitsubishi Electric”. The centrepiece of the ­exhibition shows a cross section through the world and affords profound insight into each of the five presented technology areas. Analog exhibits combined with digital media introduce visitors to the company’s technological solutions and ­versatile products.

Mitsubishi Electric is committed to having a positive nology areas are identified: Transportation, Building, impact on society. The employees working here develop, Energy, Communication and Automation. For each produce and sell technology with the goal of im­proving area, Mitsubishi Electric explains how technological so- people’s lives. This is the basic idea communicated by lutions and products change society and the life of each The robot ­demonstrations the exhibition as a whole. It shows how Mitsubishi individual for the better. In doing so, Mitsubishi Electric are impressive with their Electric expresses its corporate values and principles looks ahead and presents strategies enabling the tech- ­ingenious combination of various­ media. in practice and in product development. Five tech- nical and social challenges of tomorrow to be mastered.

Mitsubishi Electric

The exhibition – a cross section through the world. 36 Profile01/16 Profile01/16 37

Analog control elements combined with digital experience Modern building services

A trilingual exhibition folder (in Japanese, German and of the front runners: with navigation, information and And how will people cover the ever greater distances English) on “The World of Mitsubishi Electric” is available entertainment systems, sensor equipment, ­telematics within such buildings? The exhibition supplies answers for each visitor at reception. and new operator control concepts. The exhibit on to the technological challenges of modern building ser- Transportation combines analog control elements with vices. And Mitsubishi Electric has its focus not only Transportation: from A to B from A to Z digital experience. Visitors place a car or a train on an on the comfort of building occupants, but also on the Human mobility and the transportation of goods are ­interactive touch display (Mitsubishi Electric product) responsible and sustainable use of resources. The two of the major technological challenges that industry and can then intuitively discover our solutions and exhibited model of a building graphically displays the and society are having to face. Dwindling reserves ­innovations for mobility on road and rail. tasks that this technology has to perform in buildings: of fossil fuels, global warming, particulate emissions air conditioning and ventilation, lifts, safety/security and smog in cities are forcing us to rethink. Mitsubishi Building: founded on innovation equipment, information transmission and hygiene. A Electric offers solutions for today and tomorrow: boost- Due to the increase in the world population and urbani- world first is the aluminium heat exchanger for VRF air ing the efficiency of internal combustion engines and sation, more and more people are having to share less conditioning systems that operates up to 47 % more reducing pollution from them as well as strategies and and less space. The consequence is that buildings are efficiently in cooling mode than conventional products. components for electromobility and hybrid vehicles. getting taller and people spend more time in enclosed VRF stands for Variable Refrigerant Flow – as a result, And when it comes to improving comfort and safety on spaces. How will it nevertheless be possible to create an outdoor unit can cool the air in one room, for exam- road and rail, the globally active company is again one healthy, near-natural living and working conditions? ple, while serving as a heater in another. With the tablet computer, the scene comes to life – thanks to augmented reality.

Mitsubishi Electric

An opportunity to discover innovations intuitively. 38 Profile01/16 Profile01/16 39

Communication: global networking challenges of our time. Because while global demand The Information Age is founded on the swift and reliable continues to rise, resources are becoming more and transmission of ever greater quantities of data and the more scarce. At each link in the supply chain, Mitsubishi success of modern society depends on it. Mitsubishi Electric technology improves efficiency and reduces Electric supplies the components that make this pos- loss – particularly when renewable energy is integrated. sible: high-frequency semiconductors and optical ele- The Energy exhibit reports on the technological chal- ments for data superhighways without speed limits lenges posed by the integration of renewable energy as well as satellite systems and components for global sources in our power grids in the course of the energy communication. turnaround and, as an example, shows power semi- conductors that transform and stabilise the generated In the Communication area, visitors not only find infor- electricity with high efficiency and low loss. mation on products and solutions. For the cross section of the world is resolved here into the data packets and Automation: intelligence in series pixels that communication technology works with. With Teamwork pays off. This applies not only to the people the innovative Google Tango Tablet, the scene can be in a company, but also to the machines. With a broad brought to life. Augmented reality facilitates an unfor- range of mutually adapted and efficiently communicat- gettable experience as well as communicating much ing components for many production and process au- detailed information for experts and anyone interested. tomation disciplines, higher quality and productivity are They can all be here, for example, to witness “live” the brought to the shop floor – saving time, money and en- launch of a satellite into space. ergy at the same time. The visually exciting robot instal- lation playfully demonstrates the benefits of automa­ Energy: making the most of electricity tion solutions, with only the company’s own products be­ Getting energy fit for the future is one of the biggest ing used. In addition to the directly visible articulated Mastering renewable energy

robots and screens, the entire control system and in- Mitsubishi Electric TFT-LCD touchscreen. The focus is Innovative satellite technology from Mitsubishi Electric stalled servo motors come from Mitsubishi Electric. On on the benefits of these technologies and their visual the table, further products are exhibited. For each prod- representation. If required, detailed information can be uct, brief presentations can be called up at a heavy-duty retrieved at the info terminal in the product area.

Technology with the goal of ­improving ­people’s lives – this is the basic idea ­communicated ­graphically and entertainingly by the new ­exhibition.

Alexandra Blechmann PR Officer

Mitsubishi Electric

Detailed information for experts and anyone interested. 40 Profile01/16 Profile01/16 41

Mitsubishi Electric has officially opened its new EDM Technology Centre in ­Ratingen with a customer event. The turnout was remarkable.

Mitsubishi Electric

Big, bright and beautiful – the new Technology Centre Jürgen Pelzers in his reaction to the huge turnout. But in Mitsubishi Electric’s newly occupied German head- it was not only the large number of visitors that gave quarters in Ratingen was a magnet for customers. cause for satisfaction. With their thoroughly positive Big attraction. Invitations had been sent out for the official opening comments, the guests left Mitsubishi Electric in no of the new facilities on 21 and 22 April. “We received doubt about their appreciation of the new Technology Visitors flocked to the official opening. some 130 registrations, and in the end about 200 cus- Centre. Like the Training Centre, the Technology Centre tomers came,” says a gratified Sales Manager Hans- is accommodated on the ground floor of the German

Mitsubishi Electric

An unusually broad product range. 42 Profile01/16 Profile01/16 43

­headquarters in the east of Ratingen, the construc- Spelsberg KG in Schalksmühle. But even if the new tion of which was completed last autumn – well served building was a big talking point among customers, the by the A3 motorway and only 10 minutes away from focus of attention was nevertheless on the exhibited Düsseldorf Airport. “The whole building is a statement, machine park in the Technology Centre. And here again, lending expression to our strength and innovative the opinions of guests left nothing to be desired. “It’s powers as well as our goal to grow further in Germany,” certainly not commonplace to see such a big ­selection commented Akihiro Kawata, Senior Manager Industrial exhibited in one place. Mitsubishi is clearly a step Automation Machinery at Mitsubishi Electric, who had ahead of the competition in this area as well,” was the travelled to the event from Tokyo. In the spacious foyer personal verdict of Bernd Brandes, Managing Director of the new building, high-tech Mitsubishi Electric solu- of WTL Erosionstechnik in Lohfelden near Kassel. It tions and products can be seen, such as industrial was all on show – everything from start-hole drilling robots and intelligent technology for tomorrow’s energy machines and wire-cutting systems of the MV and infrastructure. In addition, by using the almost man- MP Series and the MX600 with an oil tank through high and four metre wide touchscreen, guests were to the die-sinking machines of the EA-S and EA-V also able to gather information on the Group’s prod- Series. Automation was also demonstrated in the uct range, and, importantly, a large part of the in some shape of an EROWA ro­bot on a die-sinking system. cases futuristic-looking building services come from In addition to the Technology Centre, the Training As well as talking shop, there was also time for a cappuccino or a freshly made waffle at the Fahrbarista mobile coffee stand. the company’s own product portfolio. Centre has undergone an upgrade at the new site. Wire- cutting and die-sinking systems and control simulators Exceptionally broad product range on show are all kept here to make customer training even more are short. “It is an extremely presentable Technology signing of contracts and technical discussions, there As hoped, visitors were impressed by the new build- professional and authentic. Training, seminar and con- Centre,” said Uwe Birke from Hasco Hasenclever was also time for a coffee specialty from the mobile ing and its contents. “It looks prestigious and reflects ference rooms are available with advanced equipment in Lüdenschied, putting it in a nutshell. On both days, coffee stand and for delicious finger food. In the re- the company’s standing. We feel very much at home,” throughout the new building. All areas are now clus- service and sales staff of Mitsubishi Electric showed laxed atmosphere, customers again expressed their said Dirk Stein and Jürgen Compans of Günther tered together and the walking distances for customers visitors around the facilities and explained the features appreciation of the excellent after-sales service of the of the current machines such as the maintenance-free Mitsubishi Electric team. “Their support is unbeatable,” Tubular Shaft Motor, the ingenious wire threader and said Alex Knelsen of Buschhoff Stanztechnik in Cologne, Guest from the Far East: Akihiro Kawata (centre), Senior Manager Industrial Automation Machinery, travelled from Mitsubishi Electric’s headquarters in Tokyo to the the nPV generator for nano-precision machining results. outlining his experience. “The machines are supposed official opening of the Technology Centre in Ratingen. “It is a fine opportunity to find out about new develop- ments and talk shop with the Mitsubishi experts,” said Klaus Daniels of Sieber Forming Solutions.

Praise for excellent after-sales service In addition to the general interest in the Technology Centre and machines, by no means few customers came along with definite purchasing intentions. “We always want top quality and therefore replace our ma- chines every five to six years,” reported Marcus Herse of Huf Tools in Velbert. The next wave of replacements is fast approaching, so the inauguration of the new Technology Centre was a welcome opportunity for get- ting to know the latest machines. Michael Nickel and Patrick Stüven from AES Maschinenbau in Bielefeld have made all the necessary arrangements in the last few months. “The contracts are ready for signing,” said

the two toolmakers who will take possession of a new Roughly 200 customers came on the two days of the event – many more than MV2400R wire-cutting machine in May. Alongside the expected.

Mitsubishi Electric

Talking shop with the Mitsubishi Electric experts. 44 Profile01/16 Profile01/16 45

Catching up on the latest developments, passing on tips and meeting old acquaintances – there was a lively exchange of information between customers and Die sinking, wire cutting, automation solutions and control simulators – the new Technology Centre covers an extremely wide range. ­employees on the two days of the opening. to run 24 hours a day if need be. So in an emergency, had good relations with Mitsubishi for many years. At East German combine, adding with a laugh: “That one still on hand as a consultant. His decades of experience I don’t want to be a number placed on hold, but I want to the moment, we’ve got two machines in a use, and the worked with punched cards.” After reunification, he of markets, machines and manpower are invaluable. talk to an expert without delay. Mitsubishi makes it pos- third is in the pipeline.” Aided by the service team, Ott founded his own firm. Hillig has now left the firm, but is What did he think about the new Technology Centre? sible. On top of this, the service technicians offer in some examined in detail his machine of choice, an MV2400R. “It’s become very obvious to me that Mitsubishi is still cases very pragmatic solutions that are an immediate Someone else who came along with definite plans was very forward-looking,” said Hillig. The prospects of hav- help,” Knelsen explained. Klaus-Dieter Lohse of auto- Mirko Trentzsch, Managing Director of Werkzeugbau ing long-term support from a strong partner he finds motive component supplier ZF TRW summed up the Trentzsch in Radeburg. “Our order situation is very very reassuring – and he’s not alone. exemplary service to customers in the following words: good. We’ve got two wire-cutting EDMs in operation “Mitsubishi sells its first machine through sales and the and could now do with a die-sinker so we can also second on the strength of its service.” ­machine exotic materials.” He was accompanied by Siegried Hillig, the founder of Werkzeugbau Trentzsch. Strong partner He was in fact one of the very first toolmakers to work Sometimes, it’s even more – as in the case of Dieter with a wire-cutting machine. “We bought our first ma- Ott of automotive component supplier Frimo. “We’ve chine back in 1971,” said Hillig recalling his time in an www.mitsubishi-edm.de

It’s certainly not commonplace to see such a big Green headquarters selection exhibited in one place. Mitsubishi is The new German headquarters of Mitsubishi Electric (Mitsubishi Adroit Process Suite) optimises and clearly a step ahead of the competition in this area in Ratingen is geared to eco-friendliness and automates the interplay of all the elements and cen- as well. ­energy efficiency from top to bottom. Air condition- tralises the control of the overall building services. ing, heating, lighting and water – all energy flows For its efforts, Mitsubishi Electric has received LEED Bernd Brandes and consumption have been optimised. To this end, (Leadership in Energy and Environmental Design) Managing Director Mitsubishi Electric’s Factory Automation Division Platinum status – the highest award that can be con- WTL Erosionstechnik has equipped the new building with numerous intel- ferred for resource-conserving and sustainable in Lohfelden near Kassel ligent components and products. Special software ­construction.

Mitsubishi Electric

A strong partner in the long term. 46 Profile01/16 Profile01/16 47

Ordered by 3.30 pm – delivered the next day When machines fail and replacement parts are needed parts delivery. All parts orders received via the service for repairs, time is of the essence, because an unsched- hotline or by email by 3.30 pm are processed the same uled production stoppage means stress and expense. day and sent on their way. And, if desired, express- Mitsubishi Electric’s after-sales service provides express delivered the next day as well.

The service team Martin Kuptz has been working for the ­service department for 18 years. As the Group Manager Wire-Cutting and Die-Sinking Machine Service, Mitsubishi Electric he is in charge of the assignments of ­technicians on site and for service hotline staff all over Europe. He is responsible for incoming orders and parts shipment, the organisation and plan- Service & support – ning of technician assignments and for the as- sociated accounting. The service team supports customers locally with some 1,600 assignments. holiday for your EDM. These are joined by some 20,000 inquiries by phone and email to the hotline, which are all Your holiday is booked, and the sun, the beach and relaxation are within reach. Time at last to handled by skilled staff. Via the hotline, Kuptz’s

­unwind. Experienced EDM specialists who don’t want to plunge straight back into stress on their Service Manager Martin Kuptz (centre) and the two “novices”, Christian Schneider (left) and team can swiftly settle a good 85–90 % of all in- return from their well-earned break spare their machines a thought before they leave. By running Benjamin Werner (right) quiries within an hour. through this brief checklist, you can ensure your machine gets off to a trouble-free start after a Maximum start-hole efficiency shutdown. With just a few mouse clicks, it is possible to generate of the positions and error-free transmission of all start- the exact positions of the start holes from the wire-cut- hole data. An additional postprocessor is not necessary Before your holiday After your holiday ting program. The process offers a rapid, visual control for the start-hole drilling machine. This how it works: • Check the batteries in the generator cabinet and • Install new batteries if necessary axis amplifiers and order replacement batteries if • Switch on the machine 1. Switch on the ­start-hole ­drilling ­machine 4. The drilling ­positions and wire contour are indicated necessary • Install cleaned diamond guides 2. Select the “Program” menu 5. Check the start holes • Before switching off/shutting down, run the high • Fit wear parts 3. Select the ­submenu “Indicate Wire Cutting Contour” 6. Start the program flushing for an hour • Give the machine a high flushing for about 15 minutes • Thoroughly clean the workspace • Align the wire and run the “Taper Z program” • Remove the diamond guides and clean • Check wire threading • Clean the conductance sensor and water level sensor • Start machining a test workpiece (important: only use alcohol and a brush!) • Check wear parts such as bearings and rollers, and order new ones if worn down • Check and clean filters and filter mats and replace if necessary

Avoidable overheating Maintenance should always include regular air filter needs of the machine and provide the necessary pro- ­cleaning and replacement. Filters protect the electronics tection to keep the machine up and running. False eco- and cooler from unwanted contamination and ensure nomies by installing no-name filters have been known that the components always stay cool when the going to cause cooler failure. Avoidable repair and downtime Any questions? If so, contact us at [email protected] gets hot. Original filters are precisely attuned to the costs on the four-digit euro scale are the consequences.

Mitsubishi Electric

Service – fürready Sie to da. help you. 48 Profile01/16 Profile01/16 49

Over a series of decades, Japan has undergone remarkable ­metamorphosis. Once a cultural and social backwater, the country is today a force to be ­reckoned with in the global mainstream. Its economic successes in ­particular are considerable. Japan is now the third-strongest economic power after the USA and the EU. The country owes this to its flourishing export business and highly developed technologies.

Japan Special

In sectors like automotive engin­ the Pacific nation was totally on its Nagasaki so that the Japanese had eering, machine manufac- knees at the end of World War II. no alternative but to capitulate. Mysterious Japan – ture and electronics, Japanese Its demise started with the Japanese companies have become re- armed forces’ attack on Pearl The rise after the fall nowned for unsurpassed quality. Harbour. We all know what then It was now a question of rebuild- on its way into the future. Such a feat is all the more aston­ ensued: in August 1945, the ing the country in ruins. In the initial ishing when one considers that Americans bombed Hiroshima and post-war years, Japan was still

Japan Special

The third-largest economic power after the USA and EU. 50 Profile01/16 Profile01/16 51 occupied by the Americans who erage of 10 per cent. But the surge could achieve all the goals that it ­naturally wanted at all costs to pre- of success continued thereafter. sets itself. But what is the secret of vent Japan from re-acquiring its Growth was so strong, that Japan its success? military strength. Japan ceased to overtook other industrialised na- manufacture armaments and tions, including Germany. Achieving goals through many antiquated institutions were perseverance dissolved. All available funds went In the Nineties this was halted. A A number of different factors have into reconstruction and industry. At speculation bubble that started undoubtedly contributed to Japan’s the same time, the political sphere growing in about 1985 finally burst success story. The Japanese embraced democracy. Japan got at the beginning of the Nineties. mentality and attitude to work have slowly back onto its feet. This recession was a bitter eco- certainly played their part. The nomic setback. But even this didn’t Japanese are generally considered When the Korean War broke out in hold Japan back in the long term. hard-working, tenacious and ambi- 1950, Japan aligned itself with its A country that had experienced tious. They are known to be industri- former enemy, the USA. From this such a rapid rise from nothing ous and extraordinarily dis­ciplined. point on, there was no stopping can also survive a financial crisis, When they set a goal, they do not let Japan’s recovery. It experienced a ­however serious. Japan worked up until they have achieved it. A textbook example of an Economic consistently at improving its eco- great deal is possible with targeted Miracle. What started in the Fifties, nomic situation and gradually planning and wholehearted ef- continued over the following three recovered. Japan today ranks fort. In this way various well-known decades. Economic growth was par- among the world’s biggest export- Japanese companies have become ticularly high in the Sixties at an av- ing nations. So it looks as if Japan market leaders in their sectors. The heart of the Tokyo-Yokohama region is inhabited by more than 37 million people, making it the world’s biggest conurbation.

The highway in Tokyo, Japan’s biggest city, at night.

So there’s plenty we can learn from ergy-conserving measure or a more ­cutting costs, accelerating pro­ the Japanese. On the way to suc- efficient piece of equipment. duction, attracting new customers cess, it is particularly important to or achieving greater precision. The act with deliberation and always Not every innovation works won- achievement of future goals is pos- keep one’s eyes set one’s target. A ders immediately. But that shouldn’t sible with changes, improvements company that wants to stay on the be the motivation for introducing and investments that are initiated market in the long term and maximise them. It is a question of working today. its profits must not stop investing persistently towards success. The in the future and in progress. There Japanese have never let themselves is always room for improvement. be put down, have recovered from Japanese companies are aware of their comprehensive defeat and have this and all their employees con- since become stronger than ever. stantly endeavour to optimise their They have seized all ­opportunities processes and products. Perhaps that have come their way. This we should follow their example and ­principle is applicable on the small be more open to change. Often it scale to any business. There are is utterly simple steps that achieve ­always ways and means of achiev- great things: new software, an en- ing a goal – be it a question of

Japan Special

Investment in the future and progress. 52 Profile01/16 Profile01/16 53

Founded in Punched and assembly parts for the > 300 automotive sector, household goods 1976 employees industry and medical technology

Loch’s EDM team is always true to its slogan “Always a cut above the rest!”

Wolfgang Loch GmbH & Co. KG Good planning is everything – that machines were replaced within a to be perfectly organised,” says a at least was the philosophy of the week. By the weekend, processes matter-of-fact Heiko Konrath, head EDM team of Wolfgang Loch’s busi- were running smoothly and the first of EDM and responsible for process Three in one go. ness in Idar-Oberstein when it com- workpieces were being clamped planning at Loch, who is also keen to missioned several new wire-cutting on the new machines. “When you praise the manufacturer’s engage- High precision from the gemstone town. machines of the MV Series in one replace 50 per cent of a certain ment: “We had three service techni- go last summer. Three of the six type of machine, everything has cians from Mitsubishi working here

Wolfgang Loch GmbH & Co. KG

Production to meet specific demand. 54 Profile01/16 Profile01/16 55

so that ­everything really did go as of the CAM system. The strategy Latest technologies for rapid planned.” has long paid off. Not only have pro- deliveries cesses and working methods been Despite the firm’s streamlined or- Thanks to lean management suc- optimised, but the engagement of ganisation, no two days are ever the cessfully introduced in 2009, good the company and particularly of the same. Each morning, the con- organisation and streamlined pro- workforce has been commended stantly changing jobs are discussed duction processes have meanwhile with the Lean & Green Management by the team – which is not surpris- become second nature to employ- Award for SMEs from Growth ing in view of a product portfolio that ees. “We hardly stock any spare Consulting. now covers several thousands of parts or even finished products,” pressed and assembly parts. The Marius Loch explains, the busi- 1000 tonnes for precision parts product range extends from valves ness’s Sales Manager. “As a com- The dimensions of the required for pressure cookers for the house- ponent supplier to the automotive tools are enormous: “Our automatic hold goods industry to safety-rele- industry, we are used to supplying punching presses have a pressing vant parts, such as components for just in time. This is also mirrored by force of up to 1000 tonnes, and the airbags for the automotive industry our internal processes, which we machined progressive and transfer and medical technology. Since its have managed to radically acceler- tools can be up to 4.6 metres long,” establishment in 1976, the company ate. If, for example, a plate in a tool Konrath explains. So that replace- has evolved into a globally operat- ruptures, it is immediately replaced ment parts can be produced quickly, ing enterprise with over 300 em- in next to no time by the firm’s own the company takes a somewhat ployees. Konrath sees one of the toolmaking department.” This is unusual approach. The tool parts reasons for his firm’s success in aided by the continuous data flow are made straight out of hardened the fact that it supplies everything that starts in tool design and even material. For this, it stocks blanks of from a single source and consist- Two of the three machines of the MV Series are used almost exclusively for the machining of replacement parts for the firm’s own toolmaking activities – this is the only per its modifications of the on-going twelve different material grades in ently ­invests in the latest produc- way to comply with the extremely short production times demanded. process at short notice with the aid thicknesses of 3 to 150 mm. tion technologies. Only recently, it commissioned a production con- figuration consisting of a 200-tonne press and a stamping and bending tool, we require machines that run 4700 working hours. Or, expressed ­after 300 days in service – even machine. “Only by constantly de- quickly and reliably. Sometimes, it in other words: on average, each rethreading at the wire breakage veloping – be it in technology or the is genuinely a matter of a couple of machine processes three to five point, with or without a water jet.” further training of our staff – are we hours when, for instance, parts still workpieces per day. While machines used to occasion- able to supply products of superla- have to be milled the next day be- ally break down overnight, the fail- tive quality and above all keep to cause we’ll otherwise miss the slot,” Process optimisation ure rate today is practically zero. deadlines. And these are getting Konrath elucidates. For Heiko Fuchs, another member tighter,” Konrath confirms. of the EDM team, a number of fac- He also believes that the MV Series Mitsubishi Electric wire-cut EDMs tors contribute to trouble-free pro- offers abundant opportunities for Stoppages of the firm’s own punch- have been part of the machine duction. First and foremost, there’s refining the machining process. The ing machine are not therefore an park since the mid-Eighties. “The the new wire threader of the MV Power Master tool running in the option. “When we urgently need a first machines still needed manual Series. “If it fails to thread, some- background monitors the cutting threading,” Konrath recalls. Today, thing has to be seriously wrong. process and takes remedial action five EDMs from Mitsubishi Electric No competition machine has such when wire breakage threatens or the (three MV2400Rs, an FA20S and a good threader,” says Fuchs, still contours of a corner are difficult an FA40V) are in operation almost impressed. “I originally thought that to cut. On other machines, the op- around the clock. The three new the technology was something erator himself has to intervene to machines have a high workload and that worked in the test lab, but the reduce speed. “The Mitsubishi ma- Heiko Fuchs (left) and Marius Loch scrutinising a workpiece. have already clocked up a good threader is still working perfectly chine with the Power Master does

Wolfgang Loch GmbH & Co. KG

Several thousands of pressed and assembly parts. 56 Profile01/16 Profile01/16 57

Company profile Wolfgang Loch GmbH & Co. KG

Stanztechnik und Werkzeugbau Managing Director Employees Wolfgang Loch GmbH & Co. KG Stefan Glauner, Marius Loch, > 300 Industriestraße 10 Ralf Mildenberger 55743 Idar-Oberstein, Germany Founded in Tel +49 (0) 6784 902-0 Core business 1976 Fax +49 (0) 6784 902-139 Punched and assembly parts for [email protected] the automotive sector, ­household www.loch.de goods industry and medical technology­

When machining workpieces, every hour sometimes counts – only These laterally lowered contour-cutting punches are destined for with advanced production technologies is it possible to conform to the automotive industry. the customer’s time frame.

this all by itself,” says Fuchs report- Mitsubishi machines are simply pulls his weight, particularly where Three questions to Heiko Konrath and Heiko Fuchs ing from experience. unbeatable when you consider the urgent jobs are concerned. “Each combination of precision and reli- of us is capable of handling every- Compared to the predecessor ability.” thing from programming through to Heiko Konrath Heiko Fuchs machines, maintenance costs have machining. When it comes to com- Head of EDM and EDM also shrunk to a minimum and are In fact, the Mitsubishi Electric ma- plex jobs, our many years of experi- Process Planning basically confined to annual servic- chines are not alone in contributing ence and team spirit can make all ing. The team as a whole is appre- to precision machining, for invest- the difference,” says Konrath sum- ciative of the machines’ easy access ments are currently being made in ming up. and the simplicity of replacing the air-conditioning for the EDM room wire. “We also attached great impor- so that the precision and availabil- tance to repeat accuracy,” Konrath ity of the machines are assured. adds. Konrath’s and Fuchs’s ver- So that the climate within the EDM dict is therefore unequivocal: “The team is also congenial, everyone www.loch.de

Mr Konrath, what advice would give to anyone changes, sometimes the requirements relating to buying an EDM system? the workpiece. But that’s what makes it interesting – As far as our situation is concerned, workpieces in EDM you learn something new every day. Lean management aren’t getting any smaller, so it’s important not to The lean management strategy covers all meth- Characteristic of lean management are its basic buy an undersized EDM system. Mr Fuchs, what’s the most important attribute of ods, approaches and tools that aim to establish principles of decentralisation and ­synchronisation. an EDM system operator? process-oriented business management with The two most important aspects of the lean Mr Fuchs, why do you still find EDM so exciting? Steel is just as alive as wood – be it due to micro- maximum efficiency and clearly defined proces­ ­management approach are its customer orientation Even after 17 years, there are still situations scopic changes during hardening or the introduction ses and procedures. Responsibilities and and reducing costs. These focuses can be ap­ where I’m certain that everything’s ­running of different material combinations. This also has its ­communication paths are mutually coordinated plied to both intra- and inter-company processes smoothly, and then something changes. effects on wire-cutting – nothing can replace a feel as efficiently as possible. and structures. Sometimes it’s the composition of a material that for the material.

Wolfgang Loch GmbH & Co. KG

Machines that operate reliably and quickly. 58 Profile01/16 Profile01/16 59 User horoscope.

Capricorn Aquarius Pisces Cancer Leo Virgo 21 December–20 January 21 January–19 February 20 February–20 March 22 June–22 July 23 July–23 August 24 August–23 September

You’re as fit as a fiddle and you The warm temperatures and Somehow your mind’s elsewhere A possible source of finance You love summer. And this You know all about complica- feel more alive than you’ve felt ­longer daylight hours replenish at the moment. In a state of suddenly reveals itself. A little ­explains why you’re most produc- ted workpieces. Complicated in a long time. At work you whiz your energy reserves. This is the ­confusion you wander through injection of capital would ­really tive at this time of year. You pro- people, on the other hand, are through your workpieces like a best time for thorough tidying-up your firm’s machine park like a come in handy right now. duce immaculate EDM results. always a challenge for you. And demon and after work you’re still and cleaning work. But don’t fish out of water. You need to pull Whether the investment actually Your surface quality is unbea- there’s one person who really bursting with vigour. You’ve got confine your cleaning to your yourself together right now. Find pays off in the long term de- table, your output couldn’t be pushes you to your limits. Even no intention of slowing down – home, as your EDM system out what’s bugging you and do pends on your skill. Take a strate- higher and you manage all this if it’s difficult, don’t give up – be after all, you’re not showing is bound to welcome thorough something about it. Then you gic approach and activate your at a rate that matches the cutting patient and reveal your compas- any signs of wear. This earns you treatment with the VP143 clea­n­ can get back to concentrating on inner Power Master 3D. With an speed of an MV1200S. What a sionate nature. This person is a lot of admiration. Keep up the ­er and will run even better after- your wire-cutting jobs. intelligent analysis, you’ve got performance! worth it! good work! wards. good chances of achieving your goal.

Aries Taurus Gemini Libra Scorpio Sagittarius 21 March–20 April 21 April–21 May 22 May–21 June 24 September–23 October 24 October–22 November 23 November–21 December

Watch out! You’re suddenly falling When your wire-cutting machine Don’t mistake your body for a The favourable constellations of As a Scorpio, you’re passionate If you were an MV1200S, a fault in love in a competitor’s highly starts playing up, attend to the wire-cutting machine of the FA-S the stars in the coming weeks and ambitious. Jupiter amplifies message would flash up on your advanced wire-cut EDM. This problem without delay. Doing the Advance Series. You don’t have ensure that you get almost every­ these attributes additionally. monitor. Something’s preventing is bound to cause annoyance. required maintenance now will to constantly work at top speed. thing right. And you don’t even But make sure you don’t burn you from working as efficiently Don’t hurl yourself into this ad- save you a lot of downstream You’re inclined to have the same have to make much effort. Rely up your energy prematurely. as usual. But what? Is it a problem venture – your business needs both­­er. And much the same ap- high expectations of yourself as entirely on your instinct and Otherwise you’ll produce precisi- at home? Or something at work? you. But maybe you can persuade plies to your private life. Relation­ of your machine. But this puts proceed just as intuitively as you on-eroded workpieces with mag­ A comprehensive analysis will your boss to invest in a new ships and friendships also need you under unnecessary pressure. do when operating the Advance nificently smooth surfaces, but reveal the problem so that you machine. Get your workmates to care. Tackle the problems as they Take your foot off the accelerator CNC control. If only life were al- you’ll collapse in a heap when can get back to working troub- back you up. arise rather than ignoring them a little more often – your health is ways this simple! you’ve finished. Save a little of le-free in every respect. and letting them get worse. sure to benefit. your vitality for your leisure time.

Horoscope

The stars for bright sparks.