08.10.2020

Multi-Site Tool Management 4.0

MAPAL takes over tool management at the Hitachi Automotive Systems Group in Poland, Mexico and TurkeyMAPAL takes over tool management at the Hitachi Automotive Systems Group in Poland, Mexico and Turkey

For manufacturing companies, procuring and preparing tools requires a great deal of time and effort that demands both capacity and competence. For that reason, the Hitachi Automotive Systems Group has entrusted tool management for the entire brake manufacturing process at three of its locations – in Mexico, Turkey and Poland – to MAPAL. By doing so, the company benefits not only from tool management but also from the opportunities provided by digital connectivity.

#事例研究
A Hitachi employee measures a disc milling cutter from MAPAL on the setting fixture in the configuration area.
  • A Hitachi employee measures a disc milling cutter from MAPAL on the setting fixture in the configuration area.
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    An employee measures a special disc milling cutter from MAPAL in the configuration area. Bildquelle: Hitachi Automotive Systems Group 

  • A special disc milling cutter from MAPAL is located in the measuring area of a setting fixture.
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    The Hitachi Automotive Systems Group relies on disc milling cutters from MAPAL for machining the brake calipers. Bildquelle: Hitachi Automotive Systems Group 

  • From above, a Hitachi production worker can be seen at a processing machine in the brake caliper manufacturing area.
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    At the plant in Bursa, the employees manufacture brake calipers among other things. Bildquelle: Hitachi Automotive Systems Group 

  • An employee stands in front of a UNIBASE-M tool dispensing system. Another employee walks past.
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    MAPAL has installed a UNIBASE-M tool dispensing system at the Querétaro factory. Bildquelle: Hitachi Automotive Systems Group 

  • The image shows numerous parts as they are manufactured at Hitachi Automotive Systems.
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    The tool management team invoices MAPAL at Hitachi Automotive Systems on a cost-per-part basis. Bildquelle: Hitachi Automotive Systems Group 

  • A Hitachi Automotive Systems employee wearing gloves takes a brake caliper out of the machine.
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    A Hitachi Automotive Systems employee takes the brake caliper out of the machine. Bildquelle: Hitachi Automotive Systems Group 

  • The image shows two special disc milling cutters from MAPAL.
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    MAPAL has designed disc milling cutters as custom tools in order to best fulfil the machining tasks at Hitachi Automotive Systems. Bildquelle: Hitachi Automotive Systems Group 

  • In the image, a Hitachi Automotive Systems Group employee’s hands are shown holding packaging with special cutting edges.
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    MAPAL also supplies special blades to Hitachi Automotive Systems. Bildquelle: Hitachi Automotive Systems Group 

  • A Hitachi Automotive Systems Group employee measures a brake caliper.
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    The brake calipers are subject to strict quality controls. Bildquelle: Hitachi Automotive Systems Group 

  • The image is of Hubert Klehenz, Global Purchasing Manager for Brake Systems at Hitachi Automotive Systems Group.
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    Hubert Klehenz is the Global Purchasing Manager for Brake Systems at Hitachi Automotive Systems Group. 

  • The image is of Frank Stäbler, Department Manager for Tool Management Services at MAPAL.
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    The image is of Frank Stäbler, Department Manager for Tool Management Services at MAPAL. 

The image shows two special disc milling cutters from MAPAL.
MAPAL has designed disc milling cutters as custom tools in order to best fulfil the machining tasks at Hitachi Automotive Systems. Bildquelle: Hitachi Automotive Systems Group 

Tool Management 4.0 – an impressive service

In the interests of transparency and even more efficiency, MAPAL further enhanced its conventional tool management system in 2019 and now offers Tool Management 4.0. To do so, the tool manufacturer uses an open-cloud platform from c-Com GmbH. Thanks to c-Com, MAPAL is able to illustrate the tool processes to the customer transparently and digitally.

Hubert Klehenz is pleased: “Tool Management 4.0 has definitely given us a boost when it comes to digitalisation and all its benefits for manufacturing.” He says that the direct transfer of information makes a difference – for example in the automatic restocking of inventory, which ensures that all necessary materials are available. “We have significantly more flexibility when replacing tools. As a result, the machines have noticeably less downtime,” says Klehenz, naming just one of the benefits. On top of that, Hitachi Automotive Systems Group can now digitally track its tools and receive automated reports about them.

“Having MAPAL as our tool manager gives us maximum transparency across all locations in terms of technology and machining processes – and in terms of cost,” says Klehenz. MAPAL calculates the cost per part for tool management at Hitachi Automotive Systems Group.
Hubert Klehenz lists the following tangible improvements resulting from tool management:
  • No more difficulties finding the right tool when you need it;
  • Completely accurate stock inventories – which has a positive effect on purchase costs and tied-up capital;
  • More resources for activities that add value – like brake installation – as MAPAL manages the set-up and adjustment of tools;
  • Each plant regularly receives its own key figures, making it possible to monitor the costs and outputs of individual machines;
  • Productivity is increased as a result of amendments made on the basis of these figures;
  • Hitachi Automotive Systems Group has access to the newest technologies when it comes to tools and their applications;
  • MAPAL takes care of the reconditioning of the tools, leading to a longer service life and higher maintenance efficiency.
     
An employee stands in front of a UNIBASE-M tool dispensing system. Another employee walks past.
MAPAL has installed a UNIBASE-M tool dispensing system at the Querétaro factory. Bildquelle: Hitachi Automotive Systems Group 

Global and local cooperation

It’s not just the overall global collaboration that runs like clockwork. The cooperation on-site is what’s most important. “The two head offices have made a global agreement, but it’s the local MAPAL locations that make a real difference in implementing our requirements at a regional level,” says Klehenz.

During day-to-day operations on site, the company’s production managers meet regularly with the MAPAL employees. Together, they discuss the production schedule and analyse the most important key figures. These include machine and tool failures, output figures and productivity. Every year, there are workshops at the three factories in Mexico, Poland and Turkey to share best practices and harmonise processes across the different locations. Having all the data digitally recorded by c-Com facilitates is a great help.

And cooperation is going to be significantly increased in the future: “We are now going to assess additional locations and units to identify where a similar tool management system would be helpful and increase efficiency,” says Klehenz. In doing this, the three current locations will act as model plants providing evidence of the increased efficiency. 
 
Kathrin Rehor, PR Project Manager at MAPAL

Contact

Kathrin Rehor Public Relations Kathrin.Rehor@mapal.com Phone: +49 7361 585 3342

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