Case Studies > Tulip Helps DMG MORI Digitize the Spindle Assembly Line

Tulip Helps DMG MORI Digitize the Spindle Assembly Line

Customer Company Size

Large Corporate

Region

Asia
Europe

Country

Germany
Japan

Product

Tulip I/O Gateways
Spindle Assembly Apps

Tech Stack

No-code applications
IIoT Gateways

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Productivity Improvements
Customer Satisfaction
Innovation Output

Technology Category

Platform as a Service (PaaS) - Device Management Platforms
Analytics & Modeling - Real Time Analytics

Applicable Industries

Equipment & Machinery

Applicable Functions

Discrete Manufacturing
Quality Assurance

Use Cases

Machine Condition Monitoring
Predictive Maintenance
Process Control & Optimization

Services

Software Design & Engineering Services
System Integration

About The Customer

DMG MORI is a leading international manufacturer of machines and machine tools, serving customers in over 42 industries and 79 countries. The company aims to be a 'Global One Company,' leveraging the best of their German and Japanese heritage in the modern interconnected world. DMG MORI is known for building cutting-edge innovation into each of its products and is actively taking measures to maintain its position as a leader in integrated digital innovation. The company has a strong focus on digital technology, which has become essential to manufacturing. DMG MORI's commitment to innovation is evident in their partnership with Tulip, where they are working together to reinvent the modern machine shop by developing end-to-end digital workflows and redefining the on-machine experience for frontline workers. As a large corporate entity, DMG MORI is well-positioned to implement enterprise-wide deployments of digital solutions to enhance their manufacturing processes and maintain their competitive edge in the industry.

The Challenge

DMG MORI faced challenges in improving visibility and efficiency on their spindle production line at the Deckel-Maho Pfronten facility. The production of spindles involved complex, high-mix assemblies with a single-piece flow process spanning over a dozen stations. Each station had highly variable picking procedures and quality checks, and operators relied on paper schematics and standard work requirements, which were time-consuming and prone to error. The use of paper forms made it difficult to track progress in real-time, and defects were recorded on additional paper forms, leading to slow and error-prone data analysis. The lack of real-time data hindered the identification of patterns in production data. Additionally, DMG MORI's lines adhered to strict Takt times, but without visibility into the work performed at each station, the company struggled to identify bottlenecks and properly balance lines. The existing workflows made it challenging to track work in progress through the line. To address these challenges, DMG MORI refined their digitization needs into concrete requirements, including tracking work in progress, improving visibility at each station, decreasing reliance on paper work instructions, tracking defects in-line, digitizing every station in the single-piece flow, automating defect escalation, and optimizing spindle production.

The Solution

DMG MORI chose to use Tulip to digitize their spindle assembly line, leveraging a range of Tulip's capabilities to enhance efficiency and visibility. The solution involved the development of no-code applications by DMG MORI's engineers to increase process visibility throughout their lines. These applications were built in close collaboration with operators to ensure they reflected the nuances of their work. Tulip I/O Gateways were installed at each station in the spindle assembly line, allowing DMG MORI to capture and aggregate critical production information in real-time and connect their applications to IoT devices at necessary points in the line. This setup enabled DMG MORI to capture data about each operator's performance at every station, creating complete end-to-end process visibility. The solution also included embedding schematics necessary for operators to correctly understand and execute their work, replacing static paper forms with digital access to drawings and instructions. Operators could rotate, zoom, and expand instructions as needed, improving the accuracy and speed of each step. Additionally, a digital checklist of tasks was presented to operators for each spindle, allowing DMG MORI to track station effectiveness and balance lines when bottlenecks occurred. The applications could be quickly updated to reflect changes in specifications or product lines, and in-app defect reporting allowed operators to create customized defect reports, with automatic notifications sent to shift supervisors for corrective action.

Operational Impact

Digital work instructions significantly improved the accuracy and speed of each assembly step, allowing operators to access and interact with schematics digitally.
The implementation of Tulip's no-code applications and IIoT Gateways provided complete end-to-end process visibility, enabling DMG MORI to track operator performance and optimize production lines effectively.
The digital checklist system allowed DMG MORI to monitor task completion at each station, helping to identify and address bottlenecks in the production process.
In-app defect reporting streamlined the defect escalation process, ensuring that issues were resolved quickly and efficiently, contributing to a reduction in reported defects.
The ability to update applications quickly without programming skills allowed DMG MORI to adapt to daily changes in requirements, maintaining flexibility and responsiveness in their production processes.

Quantitative Benefit