Double CNC machine productivity without replacing equipment

Automotive manufacturers and component suppliers are under growing pressure to improve machining productivity, maintain consistent quality, and respond to changing production requirements. However, upgrading an entire manufacturing facility can involve substantial investment, particularly for small and medium-sized suppliers.

DMG MORI is promoting a step-by-step approach to smart manufacturing that allows companies to modernize existing CNC machines, integrate machining processes, and introduce automation according to their operational needs.

Through its Machining Transformation (MX) strategy, the machine tool manufacturer combines process integration, automation, digital technologies, and sustainability measures to improve manufacturing performance across the production chain.

For automotive metalworking companies, the approach offers an alternative to large-scale equipment replacement, allowing manufacturers to improve existing capacity while preparing for future production requirements.

Retrofitting Existing CNC Machines to Increase Productivity

One example highlighted by DMG MORI involves German manufacturing service provider Hintersdorf GmbH & Co. KG, which upgraded an existing DMU 60 eVo linear machining center with a PH Cell 300 pallet automation system.

The retrofit was completed in just one week, enabling the machine to operate autonomously during night and weekend shifts.

According to DMG MORI, the upgrade doubled spindle runtime, while the investment paid for itself in less than one year.

Although the example is not identified as an automotive production application, it demonstrates how manufacturers can increase machine utilization without purchasing an entirely new machining center.

For automotive component suppliers, particularly those handling multiple part types and changing production volumes, retrofitting offers a potential route to higher output while making better use of existing equipment.

Combining Milling, Turning, and Grinding

Another important element of DMG MORI's strategy is process integration.

Conventional manufacturing often requires workpieces to move between several machines for turning, milling, grinding, and other operations. Each transfer introduces additional handling, setup time, and potential dimensional variation.

By combining multiple machining operations within a single setup, manufacturers can reduce process interruptions and improve machining consistency.

DMG MORI's integrated grinding technology supports internal, external, and surface grinding operations alongside milling and turning.

Depending on machine configuration and application, the company reports achievable surface accuracy values below 0.4 µm and roundness tolerances below 5 µm.

These capabilities are particularly relevant to precision automotive metal components requiring accurate geometries and high-quality surface finishes.

The company's Gear Package ALL IN 2.0 also incorporates eight machining cycles for gear production. Its gearBROACHING function enables internal and external gear teeth to be machined on turn-mill equipment without necessarily requiring a separate gear-cutting machine.

For manufacturers of transmission-related components and other precision mechanical parts, integrating gear machining into existing equipment can reduce the number of separate manufacturing operations.

Robotic Automation Connects Machining and Quality Inspection

DMG MORI is also expanding automation beyond conventional workpiece loading and unloading.

One example combines the MATRIS WPH robotic workpiece handling system with the Renishaw Equator measurement system.

The robot transfers machined components to an inspection station, where dimensional measurements are collected and used to generate correction data for the machine.

This closed-loop approach allows manufacturing deviations to be identified and corrected during production, helping maintain consistent component quality.

For automotive suppliers operating repetitive machining processes, integrating inspection with automated handling can reduce manual measurement requirements and support longer periods of unattended production.

DMG MORI also offers scalable automation systems such as Robo2Go, PH Cell, and WH Cell, allowing manufacturers to select solutions according to their production requirements.

The PH-AMR 750 autonomous mobile robot further supports material movement by transporting pallets within designated production areas without fixed rail systems.

Scalable CNC Technology for Smaller Manufacturers

Recognizing that not every manufacturer requires a fully automated production line, DMG MORI offers its Best Fit Machines (BX) portfolio.

The range includes the DMV 160 vertical milling machine, DMX 80 U five-axis machining center, and CLX 450 universal turning machine.

These machines provide a foundation for precision machining while allowing manufacturers to introduce additional automation and digital capabilities as production requirements develop.

The machines are designed for future integration with CELOS X and standardized automation solutions, including robotic loading and pallet handling.

This modular approach is particularly relevant to smaller automotive component manufacturers seeking to expand production capacity without immediately investing in complex automated systems.

Digital Tools Improve Production Planning

Alongside physical machining and automation, DMG MORI emphasizes digital manufacturing tools that support programming, production planning, and equipment management.

Its Technology Library, ESPRIT EDGE integration, and Smart Process Mapper allow manufacturers to store and reuse machining strategies and production knowledge.

CELOS X provides a digital interface connecting machine operations, manufacturing data, and shop floor personnel.

These tools can help companies standardize machining procedures, reduce programming time, and improve consistency across production teams.

For automotive suppliers managing different component specifications and recurring production orders, better access to machining information can support more efficient production planning.

A Practical Route Toward Smart Automotive Manufacturing

DMG MORI's approach demonstrates that smart manufacturing does not necessarily require replacing existing machinery or introducing complete automation in a single investment.

Instead, manufacturers can improve productivity through targeted upgrades, integrated machining operations, robotic handling, digital inspection, and more efficient use of production data.

For automotive OEMs, Tier 1 suppliers, and precision metalworking companies, these technologies offer opportunities to improve machine utilization, reduce process interruptions, and maintain consistent component quality.

The experience of manufacturers upgrading existing CNC equipment also illustrates how incremental investments can deliver measurable improvements in production performance.

As automotive manufacturing continues to demand greater flexibility and cost efficiency, step-by-step modernization may provide a practical route toward more competitive metalworking operations.