How MAPAL uses holistic manufacturing solutions to speed up processes, reduce risks and secure the future
Turnkey solutions are becoming increasingly important in modern manufacturing. They constitute holistic concepts where the solution provider takes full responsibility for planning, implementing and optimising a production process.
This not only involves the supply of individual components, but also the intelligent combination of machines, tools, fixtures and digital services. A sophisticated turnkey concept offers customers maximum efficiency and minimal interfaces, representing a very secure investment – especially in times of complex requirements and increasing demands on quality. As a full-service provider, MAPAL fulfils these criteria without exception.
Comprehensive expertise from a single source
For Stephan Köstler, Senior Director Product & Service Management, the strength of MAPAL’s approach lies in the fact that all important disciplines are integrated: from process analysis to tool and fixture design to simulation, programming and production support. Another distinguishing feature is MAPAL’s capability to assume responsibility for entire processes, according to Köstler: “We don’t just deliver components; we deliver production that runs.”
The advantages for the customers are clear: less organisational complexity, lower risks and quicker production launch. Industries with high quality requirements, sophisticated components and tight tolerances profit the most: the automotive and e‑mobility, fluid power technology, mechanical engineering and aerospace industries, for example.
Turnkey solutions take effect quickly
By assuming responsibility for processes, customers have certainty for their planning and are provided with a basis for substantiated financial decisions. MAPAL provides the relevant return-of-investment key figures to the customer: much shorter ramp-up times, stable CpK values from day one, low tool and process costs through tools and cutting data that are optimally aligned to the process and each other, and clearly documented progress through all project phases. By means of reference projects, MAPAL can also show how quickly turnkey solutions take effect and costs are recouped.
With its turnkey solutions, MAPAL offers a comprehensive service package for the development and implementation of complete machining processes – from the initial project analysis right through to series production. The aim is to optimally coordinate all process steps, thereby achieving high process reliability, maximum performance and cost-effective manufacturing processes.
Building on this, MAPAL develops and manufactures the appropriate clamping devices. From design and production right through to delivery of ready-to-use components – including dimensional and functional testing, collision analysis and comprehensive technical documentation – the entire process is managed in-house.
The design of the machining process using the most cost-effective cutting technology and the provision of ready-to-use tools is complemented by simulations, NC programming and collision checks. In this way, MAPAL ensures process stability even before the tools are put into use.
Furthermore, MAPAL supports its customers throughout process validation, series production approval and production ramp-up – including training, maintenance and support.
Fixture design is a central element of every turnkey project. As MAPAL has in-house expertise and capacities for fixture design, the group can offer everything associated with turnkey projects from a single source.
MAPAL uses a complete 3D simulation chain for this purpose. The fixture is digitally embedded in the real machine environment, and all tools and NC programs are tested for collisions. Detailed reports, 3D visualisations and reviews with the customer guarantee a seamless production ramp-up without any surprises.
Digital development of the turnkey approach
With an eye to the future, MAPAL is expanding its turnkey approach with more digital services. In the research initiatives PRODaaS (already completed) and PRODaaS@SCALE, the specialists are working on intelligently feeding real-life process data back into planning. The goal: adaptive, transparent and even more efficient processes.
