FACTORY AUTOMATION SYSTEMS

FACTORY AUTOMATION SYSTEMS SMOOTHER PRODUCTION FLOW MEANS GREATER PROFIT Automation benefits Here’s how Fastems puts you in control The key to man...
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FACTORY AUTOMATION SYSTEMS

SMOOTHER PRODUCTION FLOW MEANS GREATER PROFIT

Automation benefits

Here’s how Fastems puts you in control The key to manufacturing productivity and profit is keeping your process running smoothly. Doing so requires a continuous stream of reliable information so you can control and optimize material flow. Fastems has the software, automation tools and global support to do just that. Proven in thousands of installations around the world, Fastems systems help reduce lead times, assure product quality and enable reliable deliveries. All of which adds up to satisfied customers. Fastems Manufacturing Management Software enables you to focus on key performance targets and to easily modify them as necessary. Fastems solutions give you total control of your production. You may quickly and easily respond to changes in customer demands, plan for future expansion, accurately schedule production, and utilize capacity more efficiently.

A worldwide presence

Become competitive

Easy to use

Safe investment

Be in control

Vastly improve cycle times and throughput, reduce costs per part, efficiently adapt to changes, increase utilization rates. Simply: become more competitive!

Fastems control system is a collaboration tool for everyone involved in production. Both our software and equipment are designed with work environment, safety and ergonomics in mind.

30 years of experience. Thousands of delivered systems. We can find the optimal production solution to suit the needs of any machine shop.

Managing production is now easier than ever. Our software puts you in control of your production resources, orders, NC programs, tool presetting and more.

A privately held company founded in 1901 with world headquarters in Finland, Fastems operates in nine European countries, the United States, Japan and China, with manufacturing facilities in Finland and Germany. Fastems has 380 employees and 70 million euro turnover.

QUICK FACTS

1982

24/7

7,200

First system installed and still in use!

Technical support worldwide

Fastems record: spindle hours per year

70

380

Annual turnover (million euros)

Employees worldwide

4,000 Installed systems worldwide

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MANUFACTURING MANAGEMENT SOFTWARE MMS5 MMS5 is an open, machine tool independent system that does not require separate software for NC program, tool, material or production order management. The MMS production suite is a completely modular software solution, giving you the freedom to choose just the functionalities you need. Additionally, it’s easy to upgrade your system if your needs change over time, for example when adding manual production cells.

Usability

Integration

MMS5 provides just the right set of tools for each user. This straightforward shopfloor interface enables operators to concentrate on ”what’s hot at the moment.”

Fastems MMS5 is ready for your ERP, MES, TDM, FANUC, Siemens, Heidenhain and much more.

FASTEMS MMS CORE Program and tool data libraries, production order management, fine scheduling, diagnostics and reporting, master data management, production scheduling, and standard device interface.

MMS-2000

Deburring

MMS-7000

MMS-7100

Auto Loading

MMS-7200



Machine Tending



Dashboard

MMS-6000



Status Monitor

MMS-5000 NC



Remote Monitor

MMS-5100

MMS-4010

MMS-4230







MMS-4300

Central Tool Store*



CAD/CAM Interface *

 Operation Panel for Machine Tool Magazine*

MMS-4240





TDM System Interface*

MMS-4210







MMS-4200

Tool Data Transfer to Machine Tool* Tool Presetting Station Interface*



NC Program Transfer and Tool Checking*

MMS-4220



MMS-4100

MMS-2100

Manual Cells

MMS-2300

Material Pallet Management

Tool Identification (ID-Code)*

Integrated logistics management frees operators from repetitive tasks. It also lets you manage job lists and billets for manual production on lathes and other machines.

Whether you wish to track KPIs, investigate the effect of an urgent production order, or view a complete production scenario, you’ll have what you need in just a matter of seconds.

ERP Interface

Logistics management

Real time visibility

MMS-3010

You can predict and prevent unnecessary stops and slowdowns with centralized tool and NC program management, while optimizing fixture usage.

Proactive pallet scheduling frees your operators from juggling too many resources, thus optimizing your manufacturing process.

Automatic Material Delivery

NC program, tool and fixture management

Simulation

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* Available only for Fastems-certified machine tool interfaces.

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MMS Dashboard for production managers • Online monitoring • Performance visualization • Key production figures • User configurable widgets

MMS Data Manager for production planners • Master data management:

production orders, parts, and fixtures • Production schedule management • Production logs

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MMS Station Commander for shop floor operators • Intuitive touch screen

interface • Instructions on which parts to load and when • Advanced error recovery

All user interfaces are browser-based All user interfaces are browser-based which provides the freedom to use them anywhere with laptops or tablets.

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ROBOT CONTROL SOFTWARE The FASTWIZARD was originally developed to be a basic user interface for robot cells. One of the key drivers was to enable the use of robot cells without dedicated robot specialists. Over the years it evolved into a software platform solution with a wide array of value adding functions for easy control of the manufacturing process and the resources within. Visual User Interface: Online display for production equipment.

Order Management option. Easy management of production orders. Resource availability info for orders.

Tool management for deburring application.

Tool simulation.

FASTWIZARD benefits Easy day-to-day operation without dedicated robot experts

Visual user interface The state of your production equipment can be seen at a glance for effective system operation.

This makes it easy to use your manufacturing equipment. All machine operators can run production.

Eases your production planning Control software has many options to simplify production management. Choose manufacturing orders, resource checks and simulation functions to see how long your equipment is set up to run. This also allows you to see what changes must take place and at what time for the system to keep running.

Wide array of value adding options available Software is configured based on the needs of your manufacturing solution. The right value adding options complete your automated manufacturing process, providing optimum efficiency and quick return on investment.

OFFLINE ROBOT PROGRAMMING – FASTSIMU

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Remote Monitor

MODULE-5100

Fastems offering includes one of the most powerful software programs for offline programming and simulation. FASTSIMU is a dedicated software application for robotic milling, grinding, and deburring tasks. It includes extended in-house developed features to handle the massive number of positions needed. This is especially true for finishing complex geometry and 3D-curved surfaces, and it supports a wide range of native CAD formats. Fastems robot cells fully support offline programming. This is assured through superior mechanical accuracy and a deep understanding of offline programming methods.



CAD/CAM Interface

 MODULE-4010



NC Program Transfer and Tool Checking

MODULE-4100

ERP Interface

MODULE-3010

Sampling



MODULE-4200



MODULE-700

Parametric Part

MODULE-600

MODULE-500



Tool Data Transfer to Machine Tool



Deburring Tool Management

MODULE-400

Measuring Machine Interface

MODULE-300

Material station management



Palletizing Wizard



MODULE-310

Statistics

MODULE-200

Production Order Management

MODULE-120



MODULE-121



Parallel Part Routing

Single Part Routing

MODULE-110

ROBOT CONTROL SOFTWARE FEATURES



Program complex features off-line and save valuable production time. 9

FASTEMS 8760 SERVICE With more than 4,000 systems delivered to over 40 countries, Fastems makes customer support a priority. That’s why we have service hubs in Europe, Asia and the US for quick response to your facilities anywhere in the world.

Global response, less downtime

Fine-tune for greater profit

The 24/7 technical support team is at your service to make every one of the 8760 hours in each year as productive as possible. Our track record shows that in over 85% of cases we're able to recover the system in operation remotely, on average, in less than three hours.

We're happy to help you improve your system with diagnostic reports that enable you to quickly identify bottlenecks and fine-tune your system for greater profitability.

Lifetime software

About 80% of all systems will be modernized or extended during their lifetimes. Fastems has everything you need for minor upgrades or major extensions to continue the life and efficiency of your FMS.

Fastems software and control architecture is easily upgradable and engineered to last the life of your system when properly maintained. We provide access to control software updates, patches, error corrections and enhancements to keep your process running smoothly.

Right spares, quick delivery Genuine factory spare parts are readily available in Fastems hubs located in Europe and the US for quick shipment to your facilities anywhere in the world.

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GLOBAL SERVICE

4000 SYSTEMS

Service in Europe, Asia and US supporting you globally.

About 4,000 systems worldwide are served by our life cycle service organization.

85% SUCCESS RATE FOR REMOTE CASE SOLVING Our technical support team can solve more than 85% of service requests remotely.

80% MODERNIZED

Be ready when production needs change

Backup ensures quick recovery Regularly backed up system data is critical in case the unexpected happens. Good backups could save weeks when resuming production.

About 80% of all systems will be modernized or extended during their lifetime.

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FMS ONE

Technical information

FMS ONE is a configurable flexible manufacturing system that enables the use of a variety of machine tool sizes and pallet setup station types, while providing versatile material management. FMS ONE enhances your productivity with several key features. The scheduling and resource calculation based system, for example, offers great benefits in tool management and overall productivity. Visualization capabilities help users and management easily control changing situations.

FMS ONE benefits

SYSTEM TYPE

ONE LD-700

ONE MDR-750

ONE MDR-1100

ONE MDR-1700

ONE MD-1500

ONE XMD-2500

700

750

1,100

1,700

1,500

2,500

500 × 500

400 × 400

500 × 500

630 × 630

630 × 630

800 × 800

800 × 700 × 1,050

660 × 660 × 1,100

900 × 900 × 1,250

1,125 × 1,125 × 1,450

1,000 × 1,000 × 1,250

1,600 × 1,400 × 1,400

900

750

1,000

1,250

1,100

1,600

Material management









*

*

Material pallet size (mm)









800 × 1,200

800 × 1,200

Machining pallet storage

2–4 levels

2–4 levels

2–4 levels

2–4 levels

2–4 levels

2–4 levels

LSC

LSC, LSM

LSC, LSM

LSC, LSM

LSF, LSM

LSM

Nominal load (kg) Nominal pallet size (mm) Maximum load size (X × Z × Y mm) Load rotational diameter (ø mm)

Load station options

Modular with flexible layout

*  Available as option – Not available

2- to 4-level storage

FMS ONE is fully configurable with a broad selection of modules to be built according to your specific needs. It's available in one or two sided configurations and is easily extendable afterwards.

Logistics and material management FMS ONE includes the capability to manage raw material storage within the system.

Several pallet types It is possible to integrate different types of machine tools and pallet sizes into FMS ONE.

Full MMS5 integration A full set of integration options is available for FMS ONE.

Stacker crane The exclusive, user-friendly Fastems MMS control handles all of your production scheduling and monitoring. It seamlessly interfaces with an ERP system and CNC programs generated by CAM software. MMS easily adapts to your changing production needs and, if you prefer, you can take total or partial control.

Machine tool interface Safety equipment

Station commander 12

Loading and material stations 13

CUSTOMIZED SYSTEMS The Fastems FMS is available in a wide range of configurations from a single machine tool cell to a complex FMS that includes several makes and models of machine tools, material management, integrated robot cells, warehouse functionality, and much more. FMS seamlessly integrates into your ERP and MES systems, as well as various machine tool interfaces.

Seamless Integration Fully configurable

Material logistics

A wide variety of modules provide the most profitable approach to manufacturing. You can also select different types of pallet setup areas for various products.

It is possible to integrate your material logistics flow and billets within the system for automatic just-in-time delivery.

Multiple machine tool types

Fastest pallet transfers

Your machine tool selection is not limited to one or two types of machine tools and pallet sizes. This gives you the ability to easily change or expand production using the same FMS.

It is the highest pallet transfers-per-hour system in the market. That gives you headroom for future extensions or workpiece changes, and the ability to use it as a base for high volume production.

Extendability More than 80% are extended or modified after initial startup. You have the freedom to handle any future manufacturing scenarios.

Lights out production With optimal quantities of pallets in storage, an assisting control system and proven reliability, it is easy to reach and monitor your output targets.

User configurable widgets enable easy visualization of online monitoring, performance, key production figures, machine tool status and much more.

The FMS integrates logistics and information flow within your manufacturing process. Beginning with a layout design that maximizes shop floor utilization, and including ERP and tool management, the CNC program management system accommodates everything from single machines to factory-wide systems with multiple machine tools and all manufacturing resources. 14

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WIDE RANGE OF WORK SET STATIONS Our work set stations provide ergonomic solutions for loading and unloading your workpieces. Depending on the pallet and load size, the load can be transferred, lowered, rotated, and/or tilted to give the operator the best possible access to the workpieces. All loading stations can be accessed with an overhead crane for lifting parts and pallets. Occupational safety and health, as well as work environment and ergonomics, are taken into account. Various kinds of movable or static work platforms can be integrated into the loading area. Hydraulic or vacuum clamping can also be integrated into the loading stations, either with a manual hydraulic unit or a completely automated system.

FEATURE

LD

MD

MDR

XMD

HD

XHD

SPECIAL

Load weight (kg)

700

1,500

1,700

2,500

6,000

10,000

Custom

Machine pallet size (mm)

400–500

500–630

500–630

630–800

800–1,250

1,000–1,600

Custom

Maximum load size (mm)

800 × 700

1,250 × 1,250

1,125 × 1,125

1,600 × 1,400

2,700 × 1,700

Custom

Custom

Load height (mm)

900

1,250

1,450

1,700

2,000

Custom

Custom

Stacker crane load handler

Parallellogram

Telescopic forks

Rotating handler

Telescopic forks

Telescopic forks

Telescopic forks

Custom

Option

Option

Option

Option

Option

Option

Option

Material pallets in the same system Number of integrated machine tools

Unlimited

Brand of machine tools

Any machine tool brand available in the market

Number of pallet places

Unlimited

Control system

MMS5

In addition to machining pallets it is possible to handle wooden and metal material pallets, gitterboxes, and customer-specific loads.

Loading station flushproof LSF

Manually operated, indexable rotating pallet table. Pallet sizes up to 630 × 630 mm.

Loading station tilting LST

Loading station compact LSC

Manually operated, indexable rotating pallet table. Pallet sizes up to 630 × 630 mm.

Horizontal transfer movement, tilting of the pallet, and indexable rotating pallet table. Typical pallets sizes starting from 500 × 500 mm.

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Loading station moving LSM

Horizontal transfer movement and indexable rotating pallet table. Typical pallets sizes starting from 500 × 500 mm.

Loading station lifting LSL

Combined horizontal and vertical transfer movement and indexable rotating pallet table. Typical pallet sizes starting from 800 × 800 mm.

Material station trolley MSP For one EUR pallet.

Material station conveyor MSC Two types: for one or two EUR pallets.

Material station basic MSB For EUR or special pallets.

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TOOL MANAGEMENT Central tool logistic automation is a system for centrally delivering and managing cutting tools for CNC machines. It enables the use of small tool magazines, eliminates human errors and reduces capital investment in tools. Machine control integration enables a machine tool to start machining even if all the required tools are not in its magazine. Only the first tools to be used in the NC program must be loaded. Tool automation delivers the rest during machining.

FEATURE

CENTRAL TOOL STORAGE (CTS)

GANTRY TOOL STORAGE (GTS)

Up to 4,000

Up to 1,500

2–3

1

5

5

Max tool weight

35 kg

35 kg

Max tool length

650 mm *

650 mm *

Tools Robots Tool carriage capacity

* Customization available

Central tool storage (CTS) places a tool storage container on the factory floor next to the machine tools it services (as pictured above). A dedicated robot manages the tools in the storage container while one or two additional robots move on guideways above the machines to place the tools into the appropriate machine tool holders, and return replaced tools to storage

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Full tool life utilization

Share tools between CNC machines

The automated tool logistic system provides full tool life utilization. The tools are transported for maintenance at just the right time – not too early, not too late.

It’s possible to reduce the number of identical tools to help cut down the total amount of tools used, without sacrificing production flexibility. This is especially helpful with expensive, specialized cutting tools.

Larger amount of tools available If your production requires more tools than the number of spaces in the tool magazine, automated tool storage relieves your shop floor operators of repetitive tool carrying tasks. By equipping the machine tools with smaller tool magazines you also reduce investment costs.

Tool usage simulation Fastems MMS5 software simulates optimal work queues for your machine tools. This functionality also applies to the cutting tools. With tool automation you can minimize the number of tools needed and calculate precisely what will happen next. You don’t need to reserve all tools required for a specific job and machine tool at the beginning of a machining process.

Real time information of needed tools MMS5 tool management streamlines the flow of information. It eliminates paperwork for tool differences or future tool replacements. Plus you have full integration with the FMS control, including priority settings and standardized interfaces for many presetting devices.

Extend your lights out production period When cutting tools are no longer a production bottleneck, you can extend your lights out period even further.

Gantry tool storage (GTS) places a tool storage container above the machine tools and uses a single robot to both manage tool storage and to transfer tools between the machines and the tool storage container.

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FMS-INTEGRATED ROBOT CELLS Robotic autoloading

Robotized machine tending

With robotic autoloading your FMS is capable of large-scale, efficient serial manufacturing. By storing the materials in your FMS, you can automate your process from material management to finished parts. At the same time, the FMS control system minimizes the need to keep parts in stock and produces completed parts just in time.

By adding a robotized machine tool tending cell into your FMS, you can integrate lathes and various other types of machines into your system. This automates the material flow and keeps your machines running.

Robotized deburring and finishing Robotic solutions enables finishing, deburring, milling and heavy duty grinding applications. It ensures consistent quality and productivity, and improves work safety and ergonomics.

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FPC PLUS FPC PLUS is based on the proven Fastems FPC platform. FPC is a standard FMS constructed from container modules, allowing the integration of up to three machine tools per system. Thanks to its modular and compact construction, FPC is also a profitable investment when integrating only one machine tool. With FPC PLUS you can add optional customer specific modules including deburring and washing operations, tracking features and much more.

The RoboFMS enables automation for a wider range of machine tools, including machine tools without automatic pallet changers. Additionally, it's easy to integrate washing machines, marking machines, measuring devices and other production equipment.

Configurable

Agile

Excellent floor space utilization

Total logistics management

Whether you need standard automation or a more advanced system, including full process integration, modular FPC PLUS is your fully configurable solution.

Start with one machine tool, then extend with additional applications as needed. You have the freedom to handle any future manufacturing scenarios.

RoboFMS gives you considerable freedom for workshop layout design. You can install the robot in a stationary location or on a linear track, and position devices and buffer storage where needed.

RoboFMS makes it possible to integrate your material logistics flow and billets with your FMS for automatic, just-in-time delivery.

Control

Connect

MMS5 control links your process and FPC PLUS. It knows and shows everything that is happening and allows you to take complete control. In addition MMS5 lets you predict, plan and monitor your production cell.

Using ERP or CAD/CAM? MMS5 links your shop floor to these systems.

FPC PLATFORM

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ROBOFMS

Now have machine tools, finishing cells, measuring devices, and your complete logistic chain under one automation system.

Adding an industrial robot opens up new possibilities for handling difficult to reach production equipment and zero point fixturing. It also provides excellent operator clearance for these devices.

Lights out production

Complete FMS control

With an optimum quantity of pallets stored, an assisting control system and proven high reliability, RoboFMS is ideal for unattended operation.

RoboFMS is equipped with MMS5, the industry’s leading FMS control. MMS5 ensures seamless device and system integration, NC, fixture and tool management.

Combine several device types

FPC-750

FPC-1000

FPC-1500

FPC-3000

FPC-7500

Load weight, including pallet (kg)

750

1,000

1,500

3,000

7,500

Nominal machine pallet size (mm)

400 × 400 or 500 × 500

500 × 500 or 630 × 630

630 × 630 or 630 × 800

800 × 800 or 1,000 × 1,000

1,000 × 1,000 or 1,250 × 1,250

Load size (X × Z mm)

750 × 750

950 × 950

1,050 × 1,000

Ø 1,600

Ø 2,300

Load rotational diameter (D mm)

800

1,250

1,250

1,600

2,300

Load height, including pallet (H mm)

900

1,100

1,200

1,800

2,000

Storage capacity by container unit

12

10

10

6

4

Improved reach and accuracy

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MANUFACTURING CELLS For medium and high volume production we provide efficient and reliable gantry and robot solutions. Optimally matched handling systems and material buffers enable continuous and reliable round-the-clock manufacturing for a wide range of workpieces.

Single pass manufacturing process

Integration on multiple levels Powerful Fastems software maximizes the performance of your manufacturing system with optimum control and transparency.

Clear access and space saving

Optimal material flow

The agile movement capabilities of a robot enable you to integrate multiple processes into a true, single-pass manufacturing cell – from raw material to ready-to-pack. We can integrate a wide range of additional processes such as deburring, drilling, cleaning, marking, measuring and much more.

Unobstructed machine tool access makes setups and monitoring easy while reducing downtime. Loading from the top saves valuable floor space.

Our extensive range of material buffering systems lets you choose a gantry solution that fits to your process flow precisely.

For an optimal material flow

Also for low ceiling heights

Customized solutions

Fastems telescopic axis module is the perfect solution for facilities with restricted ceiling height.

Our modular system gives us the flexibility to design customized solutions whenever you need them.

Gantry systems

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Robotic handling cells

The wide range of Fastems material buffering systems allows you to seamlessly integrate robotic loading into your process flow.

Independent integrator Using our 30+ years of experience, we concept, design, build and deliver robotic solutions that incorporate the best, proven technologies, regardless of the brand of manufacturing equipment involved.

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Robotic finishing cells

The right spindle type for the right process

Our automated solutions for grinding, polishing, deburring, brushing and more deliver perfect results, every time. Robotic finishing cells work continuously and reliably to produce the maximum number of precisely finished parts on each shift. It's a brilliant finish to your metal-cutting process.

Pneumatic spindles

Ergonomically better Finishing tasks are among manufacturing‘s most challenging, often performed in dusty conditions while in uncomfortable positions and using noisy, vibrating tools. Having robots perform these jobs frees your workers for more productive and less physically taxing activities.

Consistent quality Because industrial robots are highly repeatable and reliable, Fastems robotic solutions ensure that your 1,000th part is just as good as your first.

The best of both worlds The finishing or deburring process is always tailored to your specific application. That’s why Fastems offers both pneumatic and electric tooling for maximum process efficiency.

Features • Available process types: ”Tool-to-Part” and

“Part-to-Tool” • Several material feeding options based on process type magazines, trays, conveyors, servo station • Readymade interface for FMS • Tool management system • Sound- or splash-proof housing for maximum ergonomics

• Programmable tools compliance to

compensate for differences. For example: part castings • Each spindle typically has one tool • Wide selection of spindles available for different applications • Typically for applications where tool amount is moderate

Electric spindles

• One spindle can handle many tools • For applications requiring a large amount of tools or where new tool implementation is frequent • Good spindle power output • Traceability of control variables • Programmable rpm

Optional accessories

• Measuring probe for part referencing • Dust extraction systems • Machine vision for optical inspection • Force control systems • Robocoat for dusty application • Coolant system for wet processes • Quality control systems • Fire suppression systems • ATEX proof

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MANUFACTURING SYSTEMS FOR HIGH MIX PRODUCTION The heart of the system is the Fastems control software. It enables parallel manufacturing of multiple orders while ensuring that production runs uninterrupted.

Management of resources

Easier production planning

The system control makes it easy to handle the various manufacturing resources needed. Missing resources are indicated, thus enabling trouble-free manufacturing.

Our control system makes is easy to plan the production for the integrated system. You have an overview of all orders in the system and the necessary resources for each.

Optimizing output without losing flexibility

Integration of manufacturing processes

The system can adapt to changes in the manufacturing environment. This means, for example, that an order with missing resources does not stop the line completely, instead the next order is processed.

You can integrate many processes under one system. This helps, for example, to eliminate unnecessary storages and transfers between processes.

You can achieve extended unmanned periods without making resource planning more complicated. By using an automated material storage system, you can extend unmanned production time to an entire weekend, for example.

Advanced software options combined with system hardware forms a true productivity solution for high mix manufacturing.

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MANUFACTURING LINES FOR HIGH VOLUME PRODUCTION Many components must be perfectly aligned with one another to keep material flowing properly. That’s why we develop the most effective interlinking solution for your automated production. We base the solution on batch size, the variety of workpieces, cycle time, available space and logistical considerations.

Output is everything

Optimal material flow

In high volume manufacturing what is most important is constant and high quality output. This is achieved by paying attention to every detail to form the best solution for each customer's process.

Automated workflow and processes increase productivity and reduce costs by shortening lead times, eliminating extra transfers, and reducing work-in-progress (WIP).

8760 Service – world wide Fastems 8760 support is there for you aroundthe-clock, 365 days, 8760 hours per year.

Space savings Automating material movement between processes and eliminating storage of work-inprogress outside the interlinking system, saves considerable factory floor space.

Maximize the value of your manufacturing line with robot cells for additional operations such as deburring, assembly, measuring and more.)

Bind manufacturing processes together with our interlinking solutions for maximum output.

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© Fastems Oy Ab / Fastems Factory Automation Systems / EN / 3 / 2016.

www.fastems.com

If you have any questions regarding the content, contact your nearest Fastems office or authorized dealer. Designs and specifications are subject to changes without notice. Fastems is not responsible for differences between the information in the catalog and the actual systems, software or other functionality.