INDUSTRY 4.0 innovative Industry 4.0 programme.
“In the old days, improving the performance of your workshop was very easy, as our move from manual machines to those using CNC shows,” Rod explains. “However, once you have made the switch to CNC machining, the improvements you make after that are not as big, and you can often hit brick walls thinking of what to do next.”
“So, once I saw Industry 4.0 and looked at the benefits it could offer Beverston, I was immediately interested. This was the perfect next step for us. We knew we needed to get started with a new project, and as we already had Mazak tools in place, it made sense to see what they could offer us.” Mazak developed its iSMART Factory™ solution to provide its customers with a way of integrating Industry 4.0 principles into their manufacturing operations. Specifically, the iSMART Factory™ concept was created in recognition that, while the benefits of Industry 4.0 were clear, the actual on- the-ground implementation could prove a barrier.
With this in mind, Mazak’s iSMART Factory™ solutions were developed to focus on data collection, utilisation and analysis, while always safeguarding manufacturing processes with the highest levels of network security, which is provided by Mazak’s SMARTBOX™ technology. The ultimate objective is more efficient factory and machine utilisation. In Beverston’s case, iSMART Factory™ solutions have been seamlessly integrated in the company’s factory and office networks, with MT Connect monitoring the machines with data exported to Smooth Monitor AX software which sits on Beverston’s server. From there the company can run data enquiries and integrate into the MRP system.
“We upgraded the network and Mazak engineers came in to install the SMARTBOX™ technology and configure our machines to work with MT Connect and the software,” says Rod. “A key concern was also security, which is extremely important in the manufacture of sensitive and safety-critical parts. Of course, if you are connected to the internet, you need to ensure this sensitive data remains secure.
“This was key to our decision to choose the Mazak SMARTBOX™ technology, as our customers were rightly demanding the highest possible levels of security. The boxes are excellent – all data now passes to and from the server through them, and are secure enough that any worried clients soon enjoyed peace-of-mind that we have met their standards.”
He continues: “The Smooth Monitor AX software has also been a good visual tool. We have a large screen on the shop floor which continually monitors the status of the machines. Everybody can see when machines are down or, if there’s an alarm, the maintenance guys can instantly see what is going on. We have screens in the office that show the managers and supervisors live information they can react to immediately.” The overall effect for Beverston has been dramatic even at an early stage of the ongoing project. By monitoring and displaying information to its office and factory team, the company has already seen a 23% reduction in setting time and downtime, and a 40 per cent relative increase in machine utilisation. These early findings are why Rod believes Beverston’s future will be bright, with additional actions expected to further establish its status as an excellent example of smart manufacturing solutions in action. “We have not even had to make massive changes to get this level of improvement, and that has been a real bonus,” Rod concludes. “It is when we further analyse this data that we expect to see even more savings and optimisation of existing processes.”
“This is absolutely what our customers want – quality products for the lowest price they can pay. iSMART Factory™ is helping us achieve that, and will be key to our competitiveness going forward. At the end of the day, investment in new technology and new practices has been what has kept Beverston improving since 1974 and led us to where we are now.”
Yamazaki Mazak
www.mazakeu.co.uk
Established in 1974, Beverston has been a Yamazaki Mazak customer since the 1980s following its move from toolmaking and workholding fixture production into CNC machining.
Yamazaki Mazak’s iSMART Factory™ solutions have been seamlessly integrated into Beverston Engineering’s factory and office networks, allowing for more efficient facility and machine utilization.
The Beverston Engineering-Yamazaki Mazak relationship endures almost 40 years later with the machine tool manufacturer supplying 23 different machines that have been crucial to the company’s continued success.
FACTORY&HANDLINGSOLUTIONS | MARCH 2022 45
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