The production of comprehensive manufacturing solutions from a single source is the main requirement for many mechanical engineering production planners. Typically, a general contractor would be responsible for the development of a complex line of interlinked machines with a variety of technologies. This provides the manufacturing company with two major benefits: the overall planning is easier (of the new factory) and a production partner that guarantees a perfectly designed, flexible, manufacturing solution, even for the most complex production situation. For years, the EMAG Group has been this partner, as it is one of the few machine builders that covers the entire process chain from soft to hard machining. Now, the experts are taking the next step with the creation of EMAG Systems and combining their project engineering expertise. The new company is the perfect partner for creating turnkey solutions, and is responsible for the overall project – combining the experience and knowledge of the various EMAG branches when necessary. 

For example, e-mobility: Here, the requirement for increased quantities  is currently shifting the focus to the establishment of comprehensive production systems. Ultimately, this is the only way to be able to produce complex components such as rotor shafts or differentials in a process-consistent and cost efficient manner. In the interlinked systems, for example, soft machining, hardening and hard machining take place in direct succession and numerous technologies from turning, drilling and milling to induction hardening and grinding are used. "When designing a complex system like this, there are naturally many questions during the planning phase," said Bernhard Böttigheimer, managing director of the new EMAG Systems. "For example, users must understand the precise benefits and performance limits of the various tool processes, opportunities for the component assessed and a reliable process developed on this basis. To compile all of this information, the user must have access to a large amount of internal technological expertise. At EMAG, we have been working toward this for years – we have a variety of core processes within the Group, and are also developing in-house automation technology."

With all of these tools at their disposal, EMAG has been enjoying growing success in the production of turnkey manufacturing solutions in recent years. The mechanical engineering company even underwent an audit by a major OEM, in which all processes and structures relating to the development of large production systems were successfully examined. The specialists regularly provide proof of their system expertise outside the automotive industry, as demonstrated by various solutions for oil production technology manufacturers. In the past, experts within the individual EMAG companies performed the corresponding project management. Why is EMAG Systems now taking on this task globally? 

"We are convinced that this business area is becoming increasingly important. The demand for complete production systems is growing because the range of products and parts is also increasing at many supplier companies and OEMs. This is putting more demand on production systems to be more flexible, and project engineering needs are being outsourced by many companies," said Böttigheimer. For these customers, EMAG Systems provides a central point of contact with experience in comprehensive turnkey production. These specialists, based in Salach, Germany, will examine each inquiry in detail, and then determine which technologies are needed for the project. With this information they will form a project team, consisting of engineers from different EMAG companies – this team will work together to form a completely customized solution for the project.

Overall, the EMAG Systems experts see their market opportunities as very positive. After all, in the automotive industry, for example, many supplier companies must position themselves much more broadly and establish independent production solutions for a larger number of different drive technologies - from the classic "combustion engine" and hybrid solutions to completely electric. 

"In this industry, the demand for our resource planning expertise is growing quickly," said Böttigheimer. A second factor in the success of EMAG Systems is Industry 4.0. After all, Smart Factories that increase the productivity of a location, or improve process reliability are impossible without comprehensive, linked systems. This is where EMAG Systems and its project engineers play a critical role. A variety of current projects shows that this full scope approach is working in the market, especially in e-mobility. For example, EMAG is currently developing two production systems for machining a rotor shaft for European customers. 

"We are clearly on the right track," Böttigheimer said. "With EMAG Systems, we intend to bring our long-standing project engineering expertise to the market in a selective manner, while continuing to grow over the next few years and at the same time pressing ahead with the technological development of production systems. We are in an ideal position for this."