Rethinking turnkey competence 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.

From project analysis to production ramp-up

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, the machining process is designed using the most cost-effective machining technology, and the tools are supplied ready for use. Simulations, NC programme generation and collision checks ensure a high level of process stability even before the actual machining takes place.

As a central element of every turnkey project, MAPAL develops and manufactures the appropriate clamping fixtures. The entire implementation – from design and production through to delivery ready for use, including dimensional and functional testing, collision analysis and comprehensive technical documentation – is handled by a single source. This is underpinned by the company’s in-house expertise and capacity in fixture manufacturing.

MAPAL also relies on a complete 3D simulation chain. The fixture is digitally embedded in the real machine environment, and all tools and NC programmes are checked for collisions. Detailed reports, 3D visualisations and close reviews with the customer ensure a smooth 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.
FOR MORE INFORMATION VISIT: https://www.mapal.com

IMAGE: Turnkey 1_Process design:

Project analysis and process design: Based on feasibility and cycle time analyses, MAPAL works with the customer to develop the optimal machining process and define the appropriate clamping concept. © MAPAL