Mazak is undoubtedly the world’s largest machine tool builder. The conglomerate with a strength of 8,331 employees on its roll, operations in 26 countries worldwide and a product portfolio covering some 260 types of systems encompassing the entire gamut of sophisticated machine tools designed to enhance flexibility, productivity and automation in the manufacturing arena, is indeed flexing its muscle and proving its mettle in spearheading technological innovations, discovers P.K. Balasubbramaniian in a one to one with Mazak India’s Managing Director, Anil Bharadwaj. Excerpts:
Q. You are a world leader in machine tools. Could you brief us on your history and present standing?
Yamazaki Mazak was established in 1919 and has been contributing to the development of the machine tool industry as the global company. Mazak manufactures not only advanced machine tools such as multi-tasking centers, CNC turning centers, machining centers and laser processing
machines, but also automation systems with the concept of ‘all in one’ to support global manufacturing by providing exceptional productivity and versatility. We use contemporary technologies and are committed to develop advanced machine tools and provide cutting-edge solutions for the progress of manufacturing as well as society.
Q. What’s your range of manufacture today?
As I said, we manufacture a range of advanced machine tools such as multi-tasking centers, CNC turning centers, vertical machining centers, double column machining centers, horizontal machining centers, CNC laser processing machines, flexible manufacturing systems, CNC systems, CAD/CAM systems and production support software, besides automation systems. In our standard range, we have something like 260 types of machines. We also make customized systems to meet specific customer needs.
Q. What’s Multi-Tasking?
Multi-tasking is when you combine several cutting processes, including turning, milling, drilling, tapping and deep-hole boring on one machine as opposed to having those same processes handled by multiple machines. When you can process an entire workpiece from raw material input to final machining in one single set-up, we refer to it as ‘done in one’ operation.
Q. Could you elaborate 5-Axis Machining?
5-Axis Machining provides infinite possibilities as to the part sizes and shapes you can effectively process. The term ‘5-axis’ refers to the number of directions in which the cutting tool can move. On a 5-axis machining center the cutting tool moves across the X, Y and Z linear axes as well as rotates on the A and B axes to approach the workpiece from any direction. In other words, you can process five sides of a part in a single setup.
Q. What’s special about your automation systems?
By automation, we refer to our so-called Palletech System. The Palletech System is exclusive to Mazak. It brings advanced, pre-engineered automation to today’s machining environments. It is a multi-tasking solution for any manufacturing or volume reqirement, and is compatible with all our horizontal machining centers as well as most of our vertical and 5-axis machining centers. With our Palletech Manufacturing Cell controller software over standard PCs and networks, shop management can monitor operations, view and change schedules on-the-fly, manage part program files from anywhere on the network, track tool life / breakage and issue instructions to the shop floor. With this system users are able to interrupt a planned machining queue and produce an emergency part with no cost penalty. That is the advantage.
Q. Could you give some idea of your production facilities and support bases network wordwide?
We have five production facilities in Japan alone. We also have manufacturing facilities in US, UK, Singapore, and China. In China itself we have two plants. Worldwide we have 83 support bases. These comprise 38 Technology Centers and 45 Technical Centers in 26 countries. Our Group companies are spread across Japan, North America, Central & South America, Europe, as well as Asia which includes Malaysia, Taiwan, Korea, Thailand, Indonesia and Vietnam.
Q. Could you throw some light on your operations in India?
Mazak India with National Head Office at Pune has its network spread all over India to cater to the customer needs. A strong workforce, especially trained in Japan helps to provide total solutions to the customer. Mazak India Head Office is spread across a 5-acre land with a built up area of 1,75,000 sq. ft. The Technology Centre showcases a spread of Multi-Tasking Machines, Horizontal and Vertical Machining Centers, Lathes and Laser Cutting Machines. The Technology Center showcases the latest and proven solutions to demonstrate the technical capabilities of Mazak India.
Q. What are the support services you offer?
If you are referring to Mazak India, we have our pan-India presence to stay closer to our customers at large. We provide online service support to our customers. Be it trouble-shooting or quick delivery of machines or spares, we are only a phone call away to reach out to the customer. In order to maintain efficient service support, the regional part center stores up to a variety of 8,000 spare parts with a total quantity of 4,50,000 items. In addition, it is connected to our Japan Global Part Center for fast and efficient response to customer requirements.
This apart, we provide extensive training in operation, programming and maintenance of our machines to all our customers. Our Technology Center is equipped with all our state-of-the-art machines and we can arrange demo of all our typical systems there.
Q. We understand you have a Spindle Rebuild Unit too. Please tell us more about this facility.
Spindle is the heart of any machine and is easily susceptible to damage due to accidents. Repair / replacement of the spindle can be expensive and time consuming. In order to support customers, Mazak India has installed a spindle cartridge repair facility with advanced testing and condition monitoring equipment such as dynamic balancing machine, test jig with simulators, vibration, temperature and lubrication monitoring devices. With the new facility, spindle repairs can be carried out quickly and at affordable costs. Mazak India also offers spindle exchange program which cuts downtime and provides the highest levels of quality and reduces costs.
Q. So what’s your differentiated offer to the Indian customer?
In today’s competitive manufacturing world where demands are high and enhanced quality, efficiency and productivity are cirtical for success, manufacturers need a machine tool partner with proven competence and who can deliver what they need and when they need it the most. And that’s exactly what they can expect from Mazak. By virtue of our technology base, global presence and wherewithal of high order, we are eminently placed to provide cutting-edge solutions, while further solidifying our position as a leader capable of providing innovative, productive and futuristic products and solutions to the end user.
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