1

Robotizing CNC machines for small

and medium series

Helmut De Roovere

CEO Aluro CNC

Reception General IT-infrastructure Finance & reporting Building infrastructure

Bending of Alu profiles www.bestbend.com

Mechanical precision parts www.aluro-cnc.com

Machines f. Insulating Alu profiles

www.aluro.com

Simply robotizing CNC www.robojob.eu

2007

Insulating Alu profiles www.isotech.be

Our organisation

Aluminium Industries OEM Manufacturing

2

2000

Market changes

1. Labor cost and gross margin

2. Bullwhip effect of the supply chain

3. Unused machining capacity

4. Decline of skilled technical staff

3

Labor cost & gross margin

2000

Market tarif CNC work 60,- €/h

Labor cost CNC operator -22,- €/h

Gross margin 21,- €/h

Machine costs -12,- €/h

Tooling costs -5,- €/h

2015

60,- €/h

-40,- €/h

3,- €/h

-12,- €/h

-5,- €/h

0 10 20 30 40

Bulgarien

Rumänien

Litauen

Lettland

Polen

Ungarn

Kroatien

Slowakei

Estland

Tschechien

Malta

Portugal

Griechenland

Slowenien

Zypern

UK

Spanien

Italien

Irland

österreich

Deutschland

Finnland

Niederlande

Luxemburg

Frankreich

Schweden

Begien

Dänemark

Labor cost EU 2014

Supply chain 2000

Part supplier OEM-Manufacture Wholesaler User

Buying Orders Assembly parts production

finished goods warehouse Parts Warehouse

4

Supply chain 2014

Part supplier

OEM-Manufacture Wholesaler User

Buying Orders Assembly parts production

finished goods warehouse Parts Warehouse

Inventory = Risky

Inventory = lying money

“The bullwhip effect of the supply chain”

Reduce inventory, avoid inventory

Production capacity

Parts production

Time

Recources

24h x 365 days = 8760 h

16h x 240 days = 3840 h

machine hours

manhours

Part supplier

Parts production

• overtime

• weekend work

• night work

• Work during holidays

• Over investment

• ... .Stress

• unemployment

• insolvency

• uncertainty

• ... .STRESS

5

War for Talent

Tendency of young people,

0 to 20 years old

Tendency of older,

65 years old

Development of the labor force

20-65 years old

Shrinkage of the working

population

Summary market changes

1. Due to globalization of the market price, and the constant rise of our labor costs, our gross margin has

decreased with ± 80%

2. The way we work is no longer adapted to the flexibility demand in the supply chain

3. Our workforce is declining, it has already become very difficult to find technical people, tomorrow it will be

more difficult.

1+2+3 = Market changes are dramatic

a structural solution is necessary

6

2015

Market tarif CNC work 60,- €/h

Labor cost CNC operator -40,- €/h

Machine costs -12,- €/h

Tooling costs -5,- €/h

Gross margin 3,- €/h

30% creative tasks

70% Repetitive tasks

For small & medium series

Mission

Possible results with the right automation systems, during normal working hours for the production of small and medium series

2000

Market tarif CNC work 60,- €/h

Labor cost CNC operator 22,- €/h

Machine costs 12,- €/h

Tooling costs 5,- €/h

Gross margin 21,- €/h

2015

60,- €/h

40,- €/h

12,- €/h

5,- €/h

3,- €/h

2015 + RoboJob

60,- €/h

13,- €/h Creative tasks

12+5=17,- €/h 5 € cost of Robot

5,- €/h

25,- €/h Back in business !!

In a two-shift system; 240 working days x 7.6 hours / shift = 3648 h / machine / year

30% of this time has to do with setting up = 1,094 h / year

Remaining is production time (3648-1094) = 2553 hours

While producing (2553 hours), you can make an additional gross margin of 22 € / h (= 25-3)

In one year, this is 56,166, - € per CNC machine (during normal working hours)

7

Possible extra results 240 working days x 8 hours per night = 1920 hours per machine per year 44 working weeks x 2 weekend days x 24 hours = 2112 hours per machine per year Total additional capacity = 4032 hours per machine per year

0 €

20.000 €

40.000 €

60.000 €

80.000 €

100.000 €

120.000 €

140.000 €

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Possible extra results

2std/Day

4std/Day

6std/Day

8std/Day

Saterday

Parts production

Time

Resourses

24h x 365 days = 8760 h

8h x 240 Tagen = 1920 Std

Machining hours

Labor hours

Part supplier

Possible production capacity with the

right automation systems

Production capacity

8

Why Robotizing CNC machines?

Realizes a separation between the creation of added-value and labor

Ensures an immediate substantial increase in gross margin

It’s the only structural solution with respect to the highly fluctuating demand as a result of the

supply chain

It makes your company structurally flexible and therefore less sensible to crises.

It is the solution to the current and growing shortage of technicians.

The role of people in production can be improved because more and more people can

concentrate on creative tasks.

This significantly increases job satisfaction.