Automation keeps manufacturing alive! - Fastems

Fastems oy Ab customer magazine 1 • 2007
Automation keeps
manufacturing alive!
Automating
production enhances
both productivity
and quality
FPM –
A new standard
for fl exibility
Manufacturing
industry experts
convene in Tampere
1 • 2007 | 1

SYSTEM
INTEGRATOR
Editorial ..................................................................2
Fastems at EMo 2007: Automation
keeps manufacturing alive! .......................3
Fastems strengths its support
in North America .............................................4
Masco and Fastems team up
to drive down cost .........................................6
“The only limit for robot cells is
our imagination” ...............................................8
Automating production enhances
both productivity and quality ..............10
FPM – A new standard for flexibility ....12
FPc raises efficiency in
small machine shops .................................14
RPc-20g increases productivity
of production machines ..........................16
Fastems and Finn-Power
cooperation expands .................................17
The multi-skilled Teleservice Team
keeps customers’ systems running ....18
Manufacturing industry experts
convene in Tampere ....................................20
Time-off ...............................................................22
Tids and bits ......................................................23
Published by FASTEMS Oy Ab
No. 1/2007
EDITOR-IN-CHIEF
Helena Reilin, Fastems Oy Ab
helena.reilin@fastems.com
ENGLISH EDITION:
Sari Lehtonen-Lammi, Imageneering Oy
LAYOUT:
Imageneering Oy
EDITORIAL ADDRESS:
System Integrator
Fastems Oy Ab
Tuotekatu 4, 33840 TAMPERE, FINLAND
Tel. +358 (0)3 268 5111
Fax. +358 (0)3 268 5000
PRINTED BY:
Kirjapaino Hermes Oy, Tampere,
Finland 2007
CONTRIBUTORS:
Tomas Agdahl
Tim Erman
Robert Humphreys
Jarmo Hyvönen
Janne Konttila
Klaus Maurmaier
2 | 1 • 2007
Matti Nurminen
Janne Näsström
Michael schott
Peter springfeld
Pekka Tuhkanen
Jens von Weissenberg
MANuFAcTuRINg
TEchNoLogIEs –
ENAbLINg
TEchNoLogIEs
E d i t o r i a l
We are facing perhaps the biggest challenge of our times. Asian economies are rising and
manufacturing focus is turning to the East. This change has begun and it will continue. In 2025,
most of the working hands between 30-40 years of age will be found in Asia. so, who is going
to do the manufacturing work in Europe and the usA? Is European manufacturing dying? No.
success factors in Europe will depend on skilled people and their efficient tools.
our strategic task is to develop these tools and see that the 8760 yearly production hours
are efficiently used despite fewer hands to do the work. With this development we don’t just
help our customers, but also the entire manufacturing industry. As manufacturing is increasingly
carried out by sMEs, it is our task to offer solutions applicable both to larger and smaller
companies. Fastems solutions will support the manufacturing strategies of both production
types. The innovative FPM concept and our new and agile robot cells provide good examples
of such products.
New manufacturing technologies need to enable fast and cost effective material flow from
bottom to top, from the first component to ready-to-use machinery. Therefore, we concentrate
on solutions that connect machine tools and technologies together without any borders or
closed standards. We offer solutions for companies who see that it is important to develop
their manufacturing strategy according to best practices and according to the latest available
technology. These companies are interested in creating effective and sustainable manufacturing.
such manufacturing allow the flexibility for future challenges.
Our goal is to ensure quality time for our customers. Time that means seeking new business
opportunities, rather than guessing what went wrong with the production equipment, why the
utilization rate of machine tools is so poor, why the throughput time too long, how staff can be
kept motivated, or how the quality level can be raised as high as possible.
At Fastems, we commit to solving those problems for you, and we want to be known for the
success of our customers. our latest solutions will be showcased at EMo 2007, in hannover.
I hope you visit us at EMo, and receive something precious to take back home. something that
will help you in your daily work, ideas that will raise your competitiveness in this ever-tightening
business, as well as tools that enable you to win the order.
Jarmo Hyvönen,
cEo
Fastems group

Fastems at EMO 2007:
Automation keeps
manufacturing alive!
PREsERvINg ThE MANuFAcTuRINg INDusTRy Is A vALuAbLE goAL ThAT FAsTEMs
shAREs WITh ITs cusToMERs.
At EMO 2007, we will continue our role as
an international pathfi nder in fl exible factory
automation solutions for lean manufacturing.
Th e latest technology highlights
showcased at EMO will be introduced also
in this magazine on pages 10‑14.
automate for more
production hours
Th e goal for Fastems products, services and
partnership is to ensure that the annually
available 8760 production hours are utilised
as effi ciently as possible. Th e over 600 FMS
and nearly 100 FPC pallet containers in-
stalled worldwide have already proven their
ability to increase global competitiveness
in the mechanical engineering, vehicle and
aerospace industries.
open doors into the
metalworKing world
Th e doors of the EMO exhibition in Hannover
will be open from 17 to 22 September 2007.
Th e absolute leading trade fair in the
world of metalworking displays on the largest
fairground premises of the world an unequalled
width and depth of products and
services throughout all production areas,
READ MORE:
pages 10-14!
from machine tools to precision tools, auto- automation
components to customised systems.
Exhibitors from all over the world once
again will put their effi ciency and innovative
power to the test before the best qualifi ed
international specialists.
Th e visitors of EMO come from all levels
of the trade, e.g. they are entrepreneurs,
board members and managing directors,
department heads as well as employees and
skilled workers. Th ey work in the fi elds of
production, operations scheduling, construction,
R+D, as well as purchasing.
1 • 2007 | 3

FASTEMS strengthen
its support in NORTH
expanded service support
In January 2006 Fastems LLC was created to
keep up with global demand for automation.
Since then Fastems LLC based near Cincinnati
has been building its support structure
for the US market. Expansion has included
service engineers based on the West Coast
and in the Mid West USA. In the latter part
of 2007 Fastems will add US based ‘teleservice’
to their support portfolio. Teleservice
enables Fastems to remotely access any
system supplied giving customers a greater
level of service support and helping to maximize
the uptime of their Fastems system/s.
deepening product support
With over 120 years of production engineering
experience, Fastems LLC product
managers, led by Vice President Robert
Humphreys, can off er our partners deep
technical support.
Pete Newbery, George Petruck and
Don Gargiulo off er this technical support
in the East, Mid West and West of the USA
respectively. Th ese highly experienced engineers
can provide automation solutions to
our customers.
4 | 1 • 2007
Robert Humphreys, VP of Fastems LLC.
it’s all aBout increased
productivity
We asked Robert Humphreys, VP of
Fastems LLC, for his take on automation,
the demands of manufacturing in North
America today, and how Fastems’ product
managers work with customers.
Q. What does Fastems automation o� er the
customer in today’s manufacturing world?
A. “Th e key to meeting the requirements
of the changing face of manufacturing is to
off er automated systems with a competitive
edge that increases productivity.”
Q. You mention the changing face of manufacturing,
what exactly do mean by this?
A. “I recently attended a Manufacturing
Summit where speakers from around the
Product Manager George Petruck,
Mid Western Area.
world presented their views of manufacturing
today in the global economy, and none
summed it better than John Byrd, the President
of AMT (Th e Association for Manufacturing
Technology). He said, ‘that although
many say that manufacturing in North
America is in decline and dying, contrary to
this manufacturing (in North America) is
in fact changing and evolving.’ Yes, there are
less people employed in manufacturing but
productivity is at its highest ever, this has
been achieved through change and investment
in technology. Th e only way to survive
is to become more productive.”
“So going back to my fi rst answer, I believe
that the systems that Fastems off ers enable
companies to change and invest in technology
that increases productivity. Th e key
words here are ‘increased productivity’.”
Q. How does Fastems LLC help and enable
customers in the US to change and evolve?
A. “Each of our 3 product managers can of-

s AMERICA
fer automation solutions that result in productivity
increases. Typically we work with
our machine tool partners and the end user
and create a production solution, the aim is
to increase productivity.”
truly flexiBle manufacturing
Next, we asked about how diff erent customers
use their Fastems systems, and what opportunities
these bring.
Q. What is a typical Flexible Manufacturing
system and does it � t a certain pro� le or
industry?
A. “Interestingly, although we have over 60
FM systems throughout North America and
Western Area
Don Gargiulo
in many diff erent industries, none fi t a typical
size or profi le. We have systems ranging
from a single machine to multi-machine
installations, some with high volume production
with low variety and many with low
volume batch production with high variety.
We have systems manufacturing parts in
aerospace through to automotive through to
medical, OEM through to subcontractors.
All systems aim to increase productivity, we
can make a one off whilst maximizing spindle
utilization, quite oft en over 90% whilst
employing minimum labor.”
Q. What would you say to customers interested
in knowing more about Fastems?
A. “I’d very much welcome any machine tool
dealer or end customer to contact one of our
product managers – aft er all, the best solutions
come from open discussion.”
System Integrator would like to thank Vice
President Humphreys for taking the time to
talk to us.
Mid Western Area
George Petruck
Eastern Area
Pete Newbery
Fastems LLC
1 • 2007 | 5

Masco Fastems
team up to drive down cost
WhILE PRoDucTIvITy Is uP IN
ToDAy’s bRAvE NEW WoRLD oF
MANuFAcTuRINg, cosT Is ThE
DRIvINg FoRcE. FLExIbILITy Is KEy
IN TWo AREAs: ThE MAchININg
cELL, AND ThosE PRovIDINg ThE
EquIPMENT. A sToRy oF shARED
vIsIoN ThAT bINDs TWo coMPANIEs
IN A sPIRIT oF PARTNERshIP.
6 | 1 • 2007
Machinery Sales Company, also called
Masco, knows that providing solutions is
good for its business – and is even more critical
to their customer’s prosperity (let alone
survival) – than selling standalone machines.
Such fl exible thinking has brought
Masco and Fastems together, in a shared
vision of “cost” and how it impacts manufacturers.
“Price, quality, delivery: that is always
the triangle,” states Garry Frost, Masco’s
President of the City of Industry, California
fi rm. “It’s very diffi cult to obtain all three.
Parts produced with too high labor content
will move to off shore production, you’ve got
to reduce operator content,” says Frost.
Four years ago Masco began to see the value
in teaming up with Fastems USA., “We
started to exploit the possibilities and realized
that Fastems FMS was the right product
for the market,” said Frost. And thus, the
seeds of partnership took root.
offer solutions, not Just
machines
Recognizing the possibility of providing
cost-driven solutions, Masco introduced
Fastems to Viking Products, Inc., where they
sold two Kitamura HX400i units combined
with a Fastems FMS. Another case is an installation
at Aluminum Precision Products
(APP), the system has helped to drive down

Bill Minna APP seen next to Fastems
system with Garry Frost of MASCO,
discussion future expansion.
costs whilst increasing productivity. Both
cases show Masco as a “solution-driven”
company.
“Fastems is very flexible, they can integrate
different machines into the same
system. This flexibility helps to bring the
solution to the cost, giving the end customer
more options. It was just sort of possibility
that APP’s Bill Minna liked.”
automating at app
“APP has a long history of cell manufacturing,”
says Frost. “Bill Minna liked the
possibility of using different machine sizes,
or even different makes of machine in the
same cell.” APP and Masco worked together
to specify the Kitamura machines with the
Fastems’ FMS and its advanced software
system.
“On an operator level, the man-cell
controller interface is very well thought out,”
continues Minna. “It allows a quick learning
curve for existing shop floor personnel.”
“APP has set its sight a high level of unattended
operation, the Fastems system is enabling
us to do just that,” adds Minna. APP
compete in a Global market, with a shortage
of workers and qualified operators they had
no choice but to automate, streamline and
go lean.
“Beautiful friendship”
People like APP’s Bill Minna have realized
that in today’s manufacturing life: either the
product is cost-competitive, or it goes offshore.
When Masco and Fastems team up
to make such good things happen, it brings
to mind Humphrey Bogart’s memorable
“Casablanca” exit line: “Louis, I think this
is the beginning of a beautiful friendship,”
concludes Frost.
Increasing
productivity
at APP
Aluminum Precision Products constantly
looks at ways to improve efficiencies and
reduce cost through lean manufacturing,
total quality management and continuous
process improvement. APP has invested in
two Kitamura HX500s and one HX630 horizontal
machining center integrated into a
Fastems MLS_MD FM system (Multi-Level
System) to achieve their goal.
One of its products, a large landing gear, exemplifies
APP’s goal of increasing productivity
through flexibility.
“With this machine tool investment we
have cut machining time from 45 to about
18 minutes,” notes APP’s machine engineering
manager, Bill Minna. Another jet
engine part was being produced at about six
parts per hour, now that part is at a rate of
8 to10 per hour, adding that “the Fastems
system enables quick reload of parts at the
load stations, helping to maximizes spindle
utilization’.
“We do many different parts a month
and run quite a bit through this cell,” adds
Minna. The 27.2m (89.2feet) long cell has
multi level storage for 42 pallets, most of
which have aluminum tombstones that APP
manufactures.
Keeping customers happy
Specializing in the forging of aluminum
and titanium precision parts, APP had a
demand to produce the aforementioned
jet engine part. “The customer asked us
to forge and machine double the previous
quantity, we needed capacity immediately”.
Masco was able to fill all our requirements
with a Kitamura HMC, 12,000 RPM spindle,
plus a number of other innovations
“We had been looking at a Fastems system
for some time, at this moment we have
three Kitamuras integrated and are considering
adding another. We won’t have to extend
the Fastems system as there is enough
space to integrate a fourth machine.”
Minna says that his operators and maintenance
personnel like the system “very
much. “They were easily trained,” he notes.
“We started installing the system about
January 4, after we came back from Christmas
shutdown, and it was up and running
by February 1. It’s been running ever since.
Reliability has been great. It has enabled us
to get greater productivity and compete in
an ever-changing market”.
1 • 2007 | 7

“The only
limit for robot
cells is our
imagination”
8 | 1 • 2007
TWo FAsTEMs RoboTIzED
PRoDucTIoN cELLs ARE hELPINg oNE
oF sWEDEN’s LARgEsT MEchANIcAL
ENgINEERINg coMPANIEs To bEcoME
EvEN MoRE coMPETITIvE.
“ThE INsTALLATIoN hAs ExcEEDED
ouR ExPEcTATIoNs,” sAys HARRY
RAjALA, PRoDucTIoN MANAgER AT
PARTNERTEch IN KARLsKogA, sWEDEN.
PartnerTech is a group of companies that
develops and manufactures products for
several of the industry’s leading brands.
They manufacture everything from telecommunications
equipment to defense
materials. The factory in Karlskoga is one
of the largest cutting machining factories
in the world, with approximately 100 CNC
machines.
Competition in the field is fierce and
PartnerTech has an ambitious investment
program. One priority is the automated
material handling. The company invests in
new machines with the required technology
and also in material handling equipment
that complements existing machines.
“Fastems presented a turn-key solution
with a portal robot that docks with the

machine,” says Kent Sandberg, who is in
charge of the investment program.
more advanced tasKs
The first robotized production cell was installed
at the beginning of 2006. It was a
Fastems RPC-20G modular portal robot that
was mounted on a 15-year-old Okuma CNC
lathe. Fastems delivered the complete system
pre-programmed and installation was over
in less than a week. After a couple of days of
training and fine-tuning, the system went
into production.
“The robot cell has functioned almost
perfectly from the very first moment,” comments
operator Tomas Forsberg.
The original idea was that the life of an obsolete
machine could be extended with the
help of a robot and the system could keep
producing at least fairly simple components.
However, the system worked so well that the
robot cell was soon assigned to more advanced
production tasks.
time for inspections
With the success of the first robot cell, the
idea to robotize another machine followed
quickly. The machine next door was an Index
G300 lathe with nine spindles and was
selected to be upgraded. The second Fastems
RPC-20G was installed at the end of 2006,
this time with the aim of fine-tuning a machine
that was used for machining advanced
components with tight tolerances. The products
in this case were defense materials that
required inspection at an individual level.
“I can now manage several machines
and I have time to inspect the products
while the robots are charging and emptying
the lathes,” says Tomas Forsberg.
“We have yet to exhaust the full potential of the robot cell. The limit is set by our imagination,”
says Harry Rajala (left) to which Kent Sandberg agrees.
The process starts by placing the blanks
on pallet trolleys in the cell. The robot picks
up one blank at a time. The control systems
of the robot and the lathe communicate with
each other and the robot loads the lathe with
work pieces. Once machining is complete,
the lathe is emptied and the robot switches
to standby mode for a moment. If the operator
presses a button, the finished work piece
is delivered for inspection through a “letterbox”.
Otherwise, the work piece is placed on
the pallet and the next blank is picked up.
“Production continues even if I do not
have the time to receive the work piece,” says
Tomas Forsberg.
flexiBle productivity
Fastems programs the robot cell on-site. The
basic program is adapted to new products
by operating the robot in manual mode and
teaching it the new operations. The process
is simple and PartnerTech was able to rapidly
change production once the potential of
the system was understood.
Both machines are operated five days a
week in a three-shift. When manufacturing
products that do not need individual inspection,
the magazine is loaded by the last shift
of the week and the machine then runs automatically
until the pallets are empty.
“We have yet to exhaust the full potential
of the robot cell. There is more to be
done. The only limit is our imagination,”
says Harry Rajala.
According to Mr. Rajala, evidence shows
that the investment is producing a better return
in terms of productivity, flexibility and
availability than PartnerTech expected.
The second robot cell was installed on one of
PartnerTech’s more advanced machines, a
nine-spindle lathe.
1 • 2007 | 9

Automating production enhances
both productivity and quality
Fastems Flexible Manufacturing System increases machine utilization
AuToMATINg MANuFAcTuRINg PRocEssEs Is oNE oF ThE MosT DEPENDAbLE
METhoDs oF INcREAsINg ThE uTILIzATIoN oF MAchINEs AND EquIPMENT,
AND ENsuRINg RELIAbLE PRoDucTIoN WITh coNsIsTENTLy hIgh quALITy. by
succEssFuL AuToMATINg MANuFAcTuRE oF ThEIR RANgE oF sAFETy vALvE
housINgs, ThE PRojEcT TEAM REsPoNsIbLE FoR vALvE boDy PRoDucTIoN AT ThE
hohENWEsTEDT PLANT oF LEsER gMbh & co. Kg, IN gERMANy, ALso AcquIRED A
sERIEs oF ExTRA RATIoNALIzATIoN soLuTIoNs IN ThE PRocEss. IN TWo hoRIzoNTAL
MAchININg cENTREs, AuToMATED FEED-IN AND REMovAL oF WoRK PIEcEs Is
PERFoRMED by A FLExIbLE MANuFAcTuRINg sysTEM FRoM ThE FINNIsh coMPANy
FAsTEMs.
Originally founded as a brassfoundry in
Hamburg in 1818, the company known today
as Leser GmbH & Co. KG has enjoyed
a success story that has lasted almost two
hundred years. Working from the outset as a
supplier, it has always concerned itself with
effective development, setting new trends
and pointing the way forward wherever possible.
The company developed its first safety
valves for use in steam boilers in 1885 and,
even back then, the safety of people and the
10 | 1 • 2007
environment was the goal of Leser products.
It was in the 1970s that the company then
switched its focus to safety valves.
Safety valves secure equipment and
pipeline systems against unwanted pressure
surges in a wide range of industrial plants,
subsequently preventing explosions and protecting
people, the environment and equipment
from injury or damage. Generally
speaking, they form the last link in the safety
chain. For this reason, it is essential that they
The Fastems MLS-MD system connects two
DBF 630 machining centres to a Flexible
Manufacturing System.
work flawlessly. This means demands with
regards to development, design and manufacturing
quality are high.
“The Leser Company is one of the world’s
leading manufacturers of quality safety
The automatic stacker crane operates shelves
with a maximum height of 20 meters and up
to 150 meters long.

valves,” says CEO Joachim Klaus with a
smile. “Our product range comprises a total of
seven product groups with 38 types of safety
valves. With a wide variety of materials and
valve sizes in nominal widths from DN 10 to
DN 400, 1/2“ to 16“, the company provides
safe solutions for all industrial applications.
Annual production is currently around 75,000
safety valves and is increasing constantly, and
we expect considerable growth in demand
for our larger safety valves in particular.” “In
light of this forecast,” adds production planning
manager Kai‑Uwe Weiss “it was decided
two years ago that a replacement investment
was necessary for two of our older machining
centres. We solved the challenges facing us
by means of an automation project, which we
called ‘Innopac’.
automation solution
requirements
“As with all automation projects”, admits
Joachim Klaus, “we too wondered how we
might solve one of the key problems, namely
how to integrate, for our business, batch size
one manufacturing orders into the automated
manufacturing process.” “Based on our team’s
experience” notes Kai-Uwe Weiss, “we added
an additional requirement in our specifications
in the call for tenders: the two machining
centres had to be capable of machining
the clamped pieces in one or at maximum
two clampings with a horizontal spindle”
“Today we know that it was precisely by
meeting this requirement”, stresses Joachim
Klaus, “that were able to achieve such good
results for rationalization. Whereas before six
or seven clampings on various machines were
necessary, we now manufacture our safety
valve housings using one or at the most two
clampings.”
rationalization solutions in
manufacturing
Matthias Hoffmann learned the job of a
machine setter in the company and became
involved in the automation project right
from the start. He says that, “all machine
pallets in the Flexible Manufacturing System
are loaded and unloaded in the two loading
stations. These carry either clamping
systems for small parts or hydraulic chain
clamping systems for machining valve housings.
This type of clamping ensures the tension
is distributed evenly across the entire
workpiece and also enhances the quality of
the processing. It’s also a lot faster, taking 30
seconds at the most.”
“The machining centres we chose”,
explains Kai-Uwe Weiss, “are DBF 630s,
which are made by Doerries Scharmann
Technologie GmbH. With these, the clampings
previously required for machining on
the lathe are no longer necessary. This was
A compact MLS-MD system (Multi-Level-System) and, from left: Machine operators Heiko
Rathjen, Matthias Hoffmann with Klaus Maurmaier, Fastems Sales Manager for Germany,
Production Planning Manager Kai-Uwe Weiss and Frank Turm, CNC Programmer.
one of the key reasons it was worth using a
Fastems Flexible Manufacturing System for
automation. Additionally though, automated
production processes ensure a high processing
quality – the machining quality of the
valve seat sealing surfaces is one of the defining
criteria for the quality of a safety valve.
Secondly, we needed to integrate an automatic
joining operation in the machining process.
This involves automatic assembly and subsequent
machining of the valve seat socket in
the safety valve housing, which is monitored
by the control system. The standard versions
of the DBF 630 machining centres also contribute
greatly to reducing the clamping work.
Bearing all these things in mind, we made
Doerries Scharmann Technologie GmbH the
general contractor for implementing our automation
plan. Doerries Scharmann then got
the Finnish company Fastems involved in the
project, whose Flexible Manufacturing System
provided the basis for fully automated operation
of the two DBF 630 machining centres.”
automated worKpiece handling
“Our goal,” says Kai-Uwe Weiss, “of having
at least every third shift unmanned could
only be achieved by automating in-feed and
removal of workpieces. The Fastems Flexible
Manufacturing System offers, as other companies
have told us, the best options for automatic
operation of machining centres. Users
of Fastems Flexible Manufacturing Systems
really do get closer to the aim of using the
8760 hours theoretically available each year
more productively. Besides the recommendation
by Doerries Scharmann, we were also
convinced of the value of the Fastems Flexible
Manufacturing System by the fact that
nearly all the best known tool machine manufacturers
have installed Fastems systems
and all speak highly of them.
“We work with cast parts,” Kai-Uwe
Weiss reminds us. “Cast parts are not always
homogenous. This means you have to reckon
on a tool break even during unmanned
night shifts.” “When this happens,” adds
Klaus Maurmaier “the machine detects the
tool break and reports this to Fastems system
control and the pallet is removed and
marked. Before continuing with a new pallet,
the FMS control system checks whether all
tools are still available, replacing broken tools
if necessary.”
fast implementation
“Even looking back today,” says managing director
Joachim Klaus, “the decision we made
shortly before Christmas 2005 with regards
to the complex rationalization project was the
correct one. The Fastems system was installed
back in September 2006 and the team that
did it was great – they assembled it within ten
days. By November the machining centres
were connected up to the Fastems Flexible
Manufacturing System. And they were wired
up to the Fastems Control System in no time
at all too – less than three days. It was at this
point we realized we were dealing with professionals.
And we were able to witness how
well it performed straight away. Even while
the automatic manufacturing system was being
commissioned, we received a large order,
which we were able to turn out rapidly.”
1 • 2007 | 11

12 | 1 • 2007
FPM
– A new standard for fl exibility
ThE FAsTEMs FLExIbLE PALLET MAgAzINE, FPM, Is A coNFIguRAbLE, FLExIbLE
MANuFAcTuRINg sysTEM ThAT oFFERs you vERsATILITy IN sIzE, MAchINE NuMbER
AND coNTRoL FEATuREs. INTRoDucED AT EMo 2007, ThE NEW gENERATIoN FPM Is
READy To ENhANcE youR PRoDucTIvITy WITh sEvERAL NEW FEATuREs.
EMO
highlights
highlights
2007

Th e Flexible Pallet magazine provides a cost eff ective alternative
for more fl exibility, when the tailored MLS system seems too big
an investment and the FPC container is not quite enough anymore.
Based on standard modules with confi gurable options, FPM creates
an ideal and easily aff ordable solution for machining workshops to
increase their automation level and unmanned production.
“FPM is a standard product that ensures fl exibility and expandability,”
says Matti Nurminen, R&D Manager of Fastems. “Th is
product has been developed to improve the effi ciency of your entire
workshop, as it can grow along with your goals from a one to ten
machine system, if needed.”
made for users
A new control system provides FPM users with an easy-to-learn
and easy-to-use graphical interface that guides and supports users
in their diff erent tasks and manufacturing operations. “Th ese control
functions are not only simple to use but also extremely fl exible,”
Nurminen emphasises. “Th e control system extends in response to
your needs and the same system supports manufacturing of both
large batches and single parts.”
“A further advantage is the working ergonomics. Th e loading
station has been designed to allow users to work in more comfortable
and ergonomic positions,” Nurminen continues.
matched with production
Th e modular system grows together with your production goals – as
far as your vision can take you. “At its smallest, the system consists
of a machine tool, loading station and storage rack for 12 machine
pallets,” Janne Konttila, Product Manager of Fastems points out.
“With extension modules you can increase the storage capacity to
more than 100 machine pallets and ten machine tools”
“Another interesting option is the multi-face machining functionality
of the control system, which enables automatic scheduling
of parts without the operator’s involvement. Th is allows making the
most urgent pieces fi rst and helps minimise the number of required
pallets and tools,” Konttila continues.
plug and produce
“Th e new generation FPM has also been designed with special focus
on quick installation and easy maintenance”, Konttila states. “Confi
gurable standard modules ensure quick installation and start-up,
which means that the investment pay-back starts rapidly,” he states.
“As a reliable system, FPM supports preventive maintenance. For in-
Matti Nurminen (left ) and Janne Konttila.
High usability with
a new generation
graphical user interface.
Th e stacker crane is
suitable for modern
MCs.
stance, easily accessible lubrication points permit servicing without
extra disassembly.”
“Of course, you can also request Fastems comprehensive service
packages and make your easy maintenance no maintenance at all.
Th is way you can concentrate solely on your core business,” Konttila
concludes.
ideal for machine manufacturers
Th e FPM’s strengths are evident not only to parts manufacturers but
also to machine suppliers who gain the opportunity to easily integrate
state-of-the-art pallet automation into their machines.
“Th e confi gurable, simple and user-friendly system is easy to
supply with diff erent machines for various customers. Th e open
control interfaces allow machine suppliers to customise their own
functionalities, such as reporting. Also, the exterior appearance can
be adapted to the machine supplier’s own colours. When needed we
will give full support for integration and training,” Matti Nurminen
says, listing benefi ts.
FPM off ers an excellent example of Fastems off ering to machine
manufacturers. “We want to serve machine suppliers with easy automation
integration. In the future, we will put even more emphasis
on the features that ensure easy supplier-specifi c customising.”
1 • 2007 | 13

ThE FLExIbLE PALLET hANDLINg coNTAINER, FPc, PRovIDEs A cosT-EFFEcTIvE
sTART ToWARDs FAcToRy AuToMATIoN AND AchIEvINg FuLL usE oF ALL 8760
PRoDucTIoN houRs IN A yEAR. ThE sTANDARD PAcKAgE hAs bEEN uPDATED WITh
NEW vALuE-ADDINg FEATuREs AND Is NoW RELEAsED As ThE FPc vERsIoN 4.0.
14 | 1 • 2007
The FPC is a standard solution for integrating
up to two equal machines in a smart way.
As such it offers new possibilities for small
manufacturers and subcontractors that are
striving for additional production output
from one or two machining centres.
FPC
raises efficiency in small machine shops

EMO
highlights
highlights
2007
attractive in price
Th e FPC provides a complete FM system in a
container. Compared to a conventional pallet
pool the FPC does not diff er much in price
but it has a smaller footprint and is more effi -
cient at delivering fi xtured components to the
Th e Fastems Flexible Pallet Container (FPC) expands from a single container unit to a full-scale
three-machine system, turning your machining centres into automated FM systems.
machine spindles. Th e FPCs are as well suited
to machining one-off s and small batches as
they are to series production.
more speed and efficiency
Modern machining centres are good at
maximising metal-cutting and minimising
air-cutting by off ering high-speed and highpower
spindles, fast axis movements and
rapid tool changes. But a machine is only able
to deliver its high production potential aft er
the fi xtured workpiece has been presented to
the spindle. Th is is where our FPC comes in,
increasing pallet turnaround speed signifi -
cantly compared with twin-APC or palletpool
systems.
start with one and expand to two
Th e container range comprises four models
covering pallet sizes from 400 mm x
400 mm up to 1,000 mm x 1,000 mm and
loads of up to 3.2 tonnes. Th e latter is the
heaviest duty system and accommodates
four pallets on one level, while the lightest
system with a 750 kg load capacity stores 12
pallets on two levels.
Only one FPC may be needed at the
outset, but a second can be retrofi tted at any
time, increasing the pallet capacity of the
lightest system to 24. At a maximum a twomachine-system
is possible.
up and running in a day
Each FPC container is confi gured to suit the
particular machining centre. Th e entire system
can be unpacked, connected electrically
and mechanically, and taken into operation
the same day.
in control
Th e FPC’s control system is based on the
Windows PC-based MMS, also used in other
Fastems systems. Th is system is responsible
for scheduling automatic pallet transfer on a
fi rst-in, fi rst-out basis between load stations
and machining centres – and via the store if
the intended machine is occupied. Manual
override is available for promoting a rush job
to the head of the queue.
every time and everywhere
A further benefi t off ered by MMS controls,
is the wealth of management data, including
machine, load station and crane utilisation
fi gures, reasons for spindle down-time, as
well as daily, weekly or monthly production
reporting.
Th is information can be available on the
factory fl oor, in the offi ce, or anywhere in
the world via the web. Machine status monitoring
and analysis provide interesting options,
as does the sending of remote alarms
via mobile phone text or e-mail messages.
1 • 2007 | 15

RPC-20G
increases productivity of production machines
FAsTEMs’ MoDuLAR RoboT cELLs cREATE A NATuRAL FIRsT sTEP FoR youR
FAcToRy AuToMATIoN. ThE RPc-20g oFFERs you A coMPLETE soLuTIoN FoR
INcREAsINg ThE PRoDucTIvITy oF youR PRoDucTIoN MAchINERy. AT EMo, WE
WILL shoWcAsE ThE LATEsT vERsIoN oF ThIs sTATE-oF-ThE-ART RoboT cELL.
Th e RPC (Robotized Production Cell) series
of robot cells enables companies to increase
the utilization rate of existing machinery with
a small investment.
RPC-G is a modular robot cell designed
for the loading and unloading of workpieces to
various CNC machines and especially lathes.
“With this cell you can easily cope with
large variations in production volumes and
with the readily available options you can
adapt it to other applications, including workpiece
fi nishing and gauging, says Ari Lylynoja,
product manager for RPC-20G.
“Th e product consists of a single transferable
unit that enables fast installation and, if
necessary, easy relocation of the system,” he
continues.
new construction for more
possiBilities
Th e updated RPC-20G has been designed
with a new and narrower construction,
16 | 1 • 2007
which reduces the required fl oor space and
minimizes the risk of transportation damage.
With its new improved construction, RPC-
20G allows for easy integration to large turning-milling
centers.
Th e new version also off ers a wider selection
of options, including automatic tool
change and a deburring brushing station, as
well as a machine vision system.
automate with minimum effort
With this robot cell both new and existing
machines can be automated with minimum
eff ort. Th e gantry concept provides good
accessibility to the machine tool in manual
mode, as well as easy implementation of diverse
material feed designs that can be geared
EMO
highlights
highlights
2007
to the workpieces, quantities, and physical
size.
“Th e RPC further allows for quick and
fl exible adaptation to today’s rapidly changing
production requirements, as well as offering
the operators more freedom for item
handling.”

FAsTEMs AND FINN-PoWER AgREE To coNTINuE MANuFAcTuRINg AND
DEvELoPINg MATERIAL AuToMATIoN coMPoNENTs FoR FINN-PoWER’s NIghT
TRAIN FM sysTEMs.
On May the 7th, 2007, Fastems and Finn-
Power signed new cooperation agreement to
manufacture and develop material automation
components for Finn-Power’s Night
Train FMS. The agreement is in force from
1.9.2007 whereafter the full supply responsibility
shifts to Fastems on 1.1.2008.
This agreement continues cooperation
between Fastems and Finn-Power, the Finnish
sheet metal turret punch machine maker.
For the last few years Fastems has already
been manufacturing stacker cranes for Finn-
Power.
leading sheet metal technology
Finn-Power is one of the world’s leading
sheet metal working technology and
machine suppliers. A significant portion
of Finn-Power’s turnover is generated by
automated cell and system products that
are capable of unmanned production. The
market demand, especially of high technology
products, is increasing and the company
supports its global development strategy
through deep cooperation with selected
partners. This cooperation aims to harness
competitive advantages from both new construction
solutions and more focused production
capacity.
growth and cooperation
One element of Fastems’ growth strategy
is to deliver proven system components to
customers outside their own direct customer
segments, and the new agreement is a good
example of this. The close cooperation be-
Tomas Hedenborg, CEO,
Finn-Power (left) and Jarmo
Hyvönen, CEO, Fastems.
Fastems and Finn-Power
cooperation expands
tween Fastems and Finn-Power offers both
parties a competitive advantage, with Finn-
Power gaining added value from the expert
partner in their own field. As such, the Finn-
Power Night Train FMS® brand will continue
to be combined with Fastems’ trade
name addition. Machine interfaces, control
systems, installation-service and spare part
services will remain at Finn-Power.
“Tight cooperation between Fastems
and Finn-Power, the leaders in their respective
fields, benefits both companies and their
customers. At Fastems, we are delighted
to be serving customers in new markets
with our technology and know-how. This is
what mutual success is all about, ” says Juha
Pihlajamaa, Product Manager, Finn-Power
products.
1 • 2007 | 17

WhEN A vIsIToR ENTERs FAsTEMs’ LoWER Lobby
IN ThE LAhDEsjäRvI oFFIcE IN TAMPERE, FINLAND,
ThE FIRsT ThINg ThEy sEE Is A gLAss WALL, bEhIND
WhIch ThERE ARE sEvERAL MoNIToRs. NExT To
ThEsE Is A gRouP oF PEoPLE FocusED oN ThEIR
WoRK AND coNTINuousLy TALKINg oN ThEIR
PhoNEs. ThIs Is A vIEW FRoM ThE hEART oF
FAsTEMs’ REMoTE sERvIcE – FAsTEMs TELEsERvIcE.
The multi-skilled
teleservice
team keeps the customers’
systems running
18 | 1 • 2007

Th e mission of Fastems’ Teleservice is to
keep both the customers’ production running
and Fastems’ 8760 promise. Teleservice
serves Fastems’ automation customers
around the clock. Teleservice is open to all
automation customers and the goal is that
all fault calls should come through Teleservice.
Th e offi cial service hours of Teleservice
are from 7 am to 4 pm CET. Calls made
outside these hours are connected to the
Call Center, from where they are directed
either to service managers or the Teleservice
team, according to a calling list.
Th e members of the Teleservice team
are, Juha Holma, Kirsi‑Maria Alho and
Jens von Weissenberg. Jari Kalliomäki will
also join the Teleservice team for the summer.
Teleservice provides strictly FMS support,
and of course sometimes the problems
may also relate to the robot cells that are
integrated to an FMS.
service in any language
“Teleservice work requires both technical
and soft ware knowledge and on top of
that you should also have good language
skills and a lot of customer service spirit”,
describes Juha. People who fulfi ll all these
criteria are few and far between, but the
members of the team have many kinds of
skills. Th e other resources available in the
company are utilized in addition to the
skills found within the team – the soft ware
team being the most important resource for
Teleservice. Also, if no one can speak the
customer’s language, the team is happy to
get help from someone at Fastems who can.
Th e main goal is to make the situation easy
for the customer.
teleservice can fix it
“Our customers can experience many
kinds of problem situations, but usually the
problem can be solved on the phone. If the
symptoms of the problem can be identifi ed,
we can oft en establish a remote connection
and fi x it remotely. It is, however, also
common that the customer cannot pinpoint
the problem. In these cases, we can usually
work out what is wrong by systematically
asking questions to identify the source of
the problem, and aft er that we can solve it,”
Timo says. “If the fault is technical, we fi nd
out which component is broken. Sometimes
the customer can change the parts
themselves, or if they cannot we will send a
mechanic from our local service offi ce. Teleservice
constantly keeps in touch with the
mechanics and electricians. If the problem
is a soft ware issue, we contact the soft ware
team: they defi nitely have the best soft ware
knowledge in the company”, describes Juha.
a team for every situation
Juha Holma also puts in a good word for
his team. “We have a good team. Our relationships
with each other are good and
everyone works enthusiastically”, tells Juha.
“Work at Teleservice requires customer
service spirit and fl exibility. At times, having
a good temper also helps. Aft er all, we
are the customer’s fi rst contact in problem
situations and sometimes they are quite upset
when they call us”, continues Juha. “Th is
work requires you to get along with people,
both coworkers and customers.”
In Teleservice work you need to be able
to separate work from your free time. Th e
work is hectic and you spend a lot of time
on the phone. Th e work is also about making
things happen, fi guring out problems
and consulting. When you leave work it
is good to be able to turn your mind away
from it and relax. Luckily all the team members
have young children who make it easy
to put work aside.
“Fastems is on a roll and we are pursuing
new customers all the time. We do not
forget our old customers though, because
they are an important resource and will
become more important when the upswing
ends. According to Fastems’ strategy we
should keep in mind the importance of existing
customer relationships.”
“All in all, work at Teleservice is interesting.
Th e work is performed locally and
there is no need to travel, but the days can
still be very diff erent. We don’t exactly receive
a lot of thanks or praise, but nonetheless
Teleservice keeps our customers’
expensive systems running and brings them
savings”, sums up Juha.
1 • 2007 | 19

Faster, more efficient, more flexible, more customer-oriented, less harmful to the environment
Manufacturing industry experts
convene in Tampere
how to Become a gloBal
marKet leader
Mikko Leino, the Director of Manufacturing
Technology Services at Nokia Corporation,
gave a speech on the first day of the conference.
He described the technology and production
strategies that Nokia uses to manage
the manufacturing of customized products
and their delivery chain on a global market.
Leino described the immense proportions
of Nokia’s manufacturing apparatus:
20 | 1 • 2007
“Nokia’s products are used by 850 million
people daily, and 11 devices are produced
every second – for a total of almost a million
devices every day. Almost 400 components
need to be produced for each device.”
Two preconditions to becoming a global
market leader are – an optimized global
delivery chain, and subcontractors that are
tightly integrated into the manufacturing
process. Customer-oriented variation is of
utmost importance for Nokia’s products, and
TAMPERE WAs oNcE AgAIN ThE
hosT FoR A sIgNIFIcANT EuRoPEAN
MANuFAcTuRINg INDusTRy EvENT. ThE
TAMPERE MANuFAcTuRINg suMMIT
2007 WAs hELD AT ThE TAMPERE
uNIvERsITy oF TEchNoLogy oN 6-7
juNE 2007. ThE sEMINAR gAThERED
TogEThER 200 REPREsENTATIvEs
FRoM MANuFAcTuRINg INDusTRy
coMPANIEs AND AcADEMIA
To DIscuss ThE DEvELoPMENT
oF INvENTIvENEss AND ThE
FuTuRE coMPETITIvENEss oF ThE
MANuFAcTuRINg INDusTRy.
Vice President Massimo Mattucci,
Comau S.p.A.
it is important to be able to implement the
variations as late as possible.
choosing the right direction
for the future
Massimo Mattucci, the Executive Vice President
of the Italian company, Comau S.p.A,
remarked that the challenges Nokia is facing
are common to the entire manufacturing
industry. It is important to quickly react to
the customer’s needs, to be close to the cus-

tomer, and to have a functional subcontracting network.
“New value-adding services and products, new business models,
and the development of industrial processes, structures and education
have been recognized as pan-European means of improving
the competitiveness of the manufacturing industry and supporting
changes in industrial structure,” Mattucci remarked.
The significance of environmental factors in industrial production
is constantly increasing. The increased awareness of the environment
presents new challenges, but on the other hand it also creates
new opportunities.
challenges for europe
“The global business environment represents a difficult challenge for
the manufacturing industry,” stated Professor Reijo Tuokko, program
coordinator of the SISU 2010 technology program from Technology
Center Hermia Ltd. Professor Tuokko went on to list several
key factors that the manufacturing industry will need to focus on
in the future: “competitiveness, increased productivity, and added
value. Likewise, inventiveness, high-quality education, and top-class
expert knowledge will also be essential. Europeans must also take
care of their own environment and its conservation. Reduction of
energy consumption and emissions affects the competitive situation
and therefore wide international cooperation is necessary.”
“The future of the manufacturing industry has been a concern
in several European countries in the past few years. The European
Union has founded a workgroup to prepare suggestions on how the
manufacturing industry will be able to prevail in Europe. Industry
remains a significant factor in promoting social welfare and for that
reason it is important to develop and take into use innovative new
approaches and methods for retaining the competitiveness of the
manufacturing industry,” said Risto Kuivanen, Vice President of
R&D at the Technical Research Center of Finland. He is also an active
participant in both the FoF and I*Proms networks.
examples of success
At the Tampere Manufacturing Summit, good examples were shown
as ways for Finnish and European companies to succeed on the glo-
Francesco Jovane.
Mikko Leino, Nokia Corporation.
bal market. Presentations on top-class European research projects
were a part of the program. These projects had sought improvements,
for example, through the use of ICT, robotics, and flexible
automation. One of the themes of the event was also the significance
of India from the European point of view, both as a market and as a
competitor.
Fastems Oy Ab was one of the organizers of the event and took
care of most of the practical arrangements, as well as the program
of the second day. At the end of the second day Fastems introduced
some practical automation solutions/products that improve productivity.
Heikki Hallila presented a new investment tool he had developed.
Janne Konttila described Fastems’ new FPM concept, which
will be officially introduced at the EMO 2007 exhibition in Hannover
in September. Jani Granholm reviewed Fastems’ latest system
control technology and Heikki Huovinen introduced Fastems’ newest
robotics applications.
After the presentations, the event participants had the chance to
take company tours at Nomet and Sisu Diesel. The company visits
received a lot of praise from the participants and served to make
Fastems’ automation solutions more tangible to the visitors.
meeting and networKing
The event participants also had the opportunity to mingle with each
other during the evening banquets. These events gave the participants
the chance to create new contacts and share experiences. At
the end of the second day Fastems held a get together for both our
Finnish and our regular European customers. This was the first time
a Fastems Quality Time Club event was extended to our customers
outside Finland. In the future we are planning to activate our regular
customer club throughout Europe.
1 • 2007 | 21

t i M E - o F F
Diving into sky
soME oF us FLy hIghER, AND MICHAEL SCHOTT, FAsTEMs sERvIcE
ENgINEER IN gERMANy hAs PuT ThIs PhRAsE INTo PRAcTIcE IN
coNcRETE TERMs. AFTER 20 yEARs oF sKyDIvINg, hE sAys, hE KNoWs
Why ThE bIRDs sINg.
We all know that Fastems technology can
take your factory automation to new heights.
But who would have guessed that a Fastems
service engineer in Germany could invite
you for a tamdem jump from 4000 metres.
“In this jump, a non-jumper without
previous skydiving experience is safely fi xed
to my stomach and we jump together,” says
Michael Schott who, with his 20 year skydiving
career, also has a licence to train students
and non-jumpers.
3,500 Jumps recorded
As service engineer, Michael helps customers
to come as near to the 8760 production
hours a year as possible. In his leisure time,
22 | 1 • 2007
he has performed altogether 3,500 skydiving
jumps.
“I did my fi rst jump together with a tandem
master in 1987. I started my fi rst course
in the beginning of 1988 and since then I
have kept going skydiving whenever it’s possible
and whenever the weather is fi ne,”
Michael explains.
160 heart Beats per minute
For those who yearn to dive into the sky, there
are two diff erent ways to learn these skills.
“Th e conventional way is to make your
fi rst jump alone with a static line, which is
fi xed to the aeroplane and opens the parachute
automatically,” Michael says.
Michael Schott has 20 year skydiving career.

“Th e other possibility is AFF, Accelerated Free Fall, and then you
do the fi rst jump together with two instructors and pull your parachute
alone. Th e conventional training takes about four weeks, whereas the
AFF method can be carried out in fi ve days,” he continues.
“No matter if you choose conventional or AFF, you must always be
in excellent physical health because during a skydive jump your heart
beats up to 160 beats per minute,” Michael warns.
team spirit
Michael’s work is a combination of technological know-how and cooperation
skills. He has to understand and solve the technological problems
on customer sites, but it is as important to be able to communicate with
other experts. Teamwork is a key issue.
Enjoying the team spirit is also part of skydiving: “My favourite part
of skydiving is when a group of a minimum of two people fl y together to
form various fi gures. At the moment, the world record in this discipline is
400 people fl ying at the same time.”
“i Know why the Birds sing”
“When fl ying in the sky, I feel happy and concentrated. I focus on playing
my role in the formation correctly,” Michael says, describing his feelings
in the sky. “In addition to my own jumps, I enjoy teaching my students.
Th e goal is that they will be able to share the same unique feeling.”
“To put briefl y: Skydivers know why the birds sing. Flying in the sky
takes your troubles away, makes you feel free and without sorrow.”
t i d S & B i t S
new power in germany and usa
GERMANY, FASTEMS GMBH
Matti Kangas, service engineer, who started
on 1.12.2006, takes now care of service support
with eff ect from 1.7.2007.
Alex Becker, service technician for FMS
systems, started on 1.2.2007.
Andreas Gröbner, technician for electric
assembly is in charge of FMS commissioning,
eff ective from 1.3.2007.
Michael Stumpf, sales manager for Benelux,
started on 2.5.2007.
USA, FASTEMS LLC
George W. Petruck started as Product Manager
on 19.3.2007. He takes care of customer
support in the Mid-West region of the United
States of America.
Carol Haas started as Project Manager on
2.7.2007 based in West Chester she will be
responsible for all projecting matters.
Howard ‘Butch’ Clough takes care of Teleservice
since 14.5.2007, Butch will off er
customer remote connection support to help
maintain productivity of installed systems.
8760 hours
at your service
1 • 2007 | 23

INNOVATION
A fl exible
standard
Fastems’ EMO 2007 innovation – the FPM (Flexible Pallet Magazine) manufacturing
system – is the new standard in fl exible manufacturing. It is
developed for professionals like you, who want more than standard but are
unwilling to pay the high cost of customization. Thanks to its confi gurable
modules, the user-friendly FPM is ready to grow with your business.
Join us at emo 2007 in hannover from september 17 to 22 for more
top moments in fl exible manufacturing.
Our stand is located in hall 12, section B100.
fastems oy ab
Bultgatan 40 B
Via Bruno Buozzi, 61
Tuotekatu 4
S-44240 Kungälv, Sweden I-20097 San Donato
FI-33840 Tampere, Finland Tel. +46 (0)303 246 900 Milanese (MI), Italy
Tel. +358 (0)3 268 5111
Fax +46 (0)303 246 910 Tel. +39 02 365727.23
Fax +358 (0)3 268 5000
Hawley Mill-Hawley Road
Fax +39 02 365727.24
Hakkilankaari 2
Dartford, Kent DA2 7SY Fastems UAB
FI-01380 Vantaa, Finland
United Kingdom
Kalvarijos str. 38
Tel. +358 (0)9 3450 48
Tel. +44 (0)7818 427133 LT-46346 Kaunas, Lithuania
Fax +358 (0)9 3450 5623
Fax +44 (0)1322 282250 Tel. +370 37 291567
Heilbronner Straße 17/1
99, rue de Gerland
Fax +370 37 291589
D-73037 Göppingen, Germany F-69007 Lyon, France Fastems LLC, 9850 Windisch Road
24 | 1 • 2007
Tel. +49 (0)7161-963 800
Fax +49 (0)7161 -963 8049
Tel. +33 (0)4 3765 2000
Fax +33 (0)4 3765 2001
West Chester, Ohio 45069, USA
Tel. +1 513 779 4614
www.fastems.com