To modernize the production of a large customer, MAPAL has taken new paths in Indonesia. The local branch of the tool manufacturer from Aalen supplies an automotive supplier not only with tools for minimal quantity lubrication (MMS) but has also taken over sales and service for the systems.
Astra Otoparts is one of the largest automotive suppliers in Indonesia. Customers of the company, founded in 1976, include numerous well-known automotive and motorcycle manufacturers from Japan, South Korea, and Europe. The group consists of more than 50 manufacturing companies. One of them is Astra Otoparts Nusametal, which produces components from aluminum die casting through mechanical processing to the finished product.
Like many other companies in the country, Astra Otoparts is also confronted with growing demands for environmental protection. The government is urging industrial companies, especially the automotive sector, to produce 'greener'. This aligns well with the image of Astra Otoparts. In recent years, the company has repeatedly distinguished itself with environmental initiatives, such as for clean water, reforestation, and biodiversity. Recently, the focus has been on the protection of the Javan gibbon.
High productivity in confined spaces
Stricter environmental regulations were not the only reason for Astra Otoparts' Nusametal business unit to consider the production of the future. Like the headquarters of Astra Otoparts, this plant is also located in North Jakarta, one of the most densely populated areas of the island nation. The company is growing, yet the need for more efficient processes with better quality and increased production capacity with the existing machines remains a challenge. This is where MAPAL came into play.
The tool manufacturer's branch started in Jakarta in 2014 and now offers its product and service portfolio at three additional locations on Java with more than 20 employees. The customers mainly come from the automotive sector, with scooter manufacturers being a focus in Indonesia. Often, MAPAL Indonesia also supports machine manufacturers in projects for Japan or India. Solutions developed in Jakarta with automotive companies have already been transferred to production sites in Taiwan, Vietnam, and Thailand.
Minimal quantity lubrication as a productivity lever
During a seminar, Nusametal became aware of MMS technology. MAPAL demonstrated the use of PKD tools with minimal quantity lubrication, which promised a significant improvement in aluminum processing. In addition to the known advantages of processing with MMS, particularly in the fine machining of aluminum alloys, a better surface quality is achieved compared to processing with conventional cooling lubrication with emulsion. Reasons for this include the better lubricating effect of the MMS media and the absence of small particles that are not filtered out by conventional cooling lubrication systems.
Minimal quantity lubrication has been experiencing a boom in the industry in recent years in the context of resource conservation and energy efficiency. MAPAL offers nearly all of its tools in variants for MMS and marks them with a green label. In these green tools, the cooling channels are modified to ensure optimal supply of the MMS medium to the cutting edges and guiding surfaces of the tools.
Project for switching to MMS
At Nusametal, the potential of the technology for its own production was immediately recognized. The use of MMS would reduce costs for coolants, increase productivity, decrease water consumption, and improve the working conditions in the production area. Furthermore, the lower energy consumption also reduces the company's CO2 footprint. Nusametal's strong interest resulted in a joint project with MAPAL Indonesia to retrofit existing machines for MMS. The company DropsA, as the manufacturer of the MMS systems, was also involved.
Initially, a major handicap was the fact that DropsA has no representation in Indonesia. After some considerations, MAPAL Indonesia ultimately took over the import and installation of the MMS devices. Until that point, the team in Jakarta had no experience with minimal quantity lubrication. 'We knew this would be a challenge, as we first had to get to know the device and acquire the knowledge for its installation, use, and repair,' reports Andreas Wasisto, Managing Director of MAPAL Indonesia.
Employees from Nusametal and MAPAL Indonesia familiarized themselves with the technology at DropsA in Frickenhausen and Milan.
As for the tool manufacturer, the cooperation is also unusual for DropsA and has so far been unique in this form. Sales manager Frank Müller speaks of a fruitful collaboration and a good relationship between the two companies. 'MAPAL is a very good partner for us because the tool manufacturer is very close to the customer and the experts there bring a lot of application knowledge,' says Müller.
The connection of the 1-channel MMS systems to the existing BT30 machines from Fanuc Robodrill proved to be relatively straightforward. Furthermore, considerations had to be made regarding chip removal, later cleaning, placement of the MMS device, maintenance, and the use of suitable lubricants. This part was completed in close collaboration between MAPAL Indonesia, Nusametal, and their sister company Astra Otoparts Winteq.
Faster to the crankcase cover
The pilot project was a success. Nusametal initially used the retrofitted machines for the production of crankcase covers for scooters from a Japanese manufacturer. The company produces around 11,000 of these aluminum components daily on a total of 24 machines configured in six production lines. The MAPAL tools are used for rough and finish machining and are each equipped with several PKD cutting edges.
Additionally, face mills with interchangeable PKD cutting inserts and PKD-tipped form mills are used. Drills and thread formers are made of solid carbide. Compared to competitor tools, the MAPAL tools reduced the machining time by about 20 percent.
At Nusametal, there is great satisfaction with the progress made, as Rachmad Basuki, Engineering Department Head of the Nusametal business unit of Astra Otoparts, confirms: "The collaboration between the engineers of the Nusametal business unit of Astra Otoparts and MAPAL Indonesia has played a crucial role in improving tool design and internal optimizations at Nusametal. This partnership has increased overall production performance and demonstrated the capability of cross-functional synergy effects in engineering. The advanced technologies and innovative solutions introduced through this collaboration have become a catalyst for further improvements across the entire production area."
These include, among other things, layout optimization, automation initiatives, and the development of fixtures and holders. The use of PKD tools with MMS has led to faster processing times and thus higher performance, significantly increasing the daily production volume.
In production, additional advantages were observed due to the switch to MMS. The work area remains significantly cleaner. The components are dry after processing, eliminating the need for a labor-intensive washing process. The longer tool life and the resulting reduced machine downtime contribute to higher productivity and lower tool costs.
"The MMS project of the Nusametal business unit is one of the most significant projects of our company," emphasizes Willy, Deputy Chief Operating Officer of the Nusametal business unit of Astra Otoparts, explaining that the implementation has already been expanded beyond the production line for CVT gearbox housings.
Currently, 24 out of 150 machines are operating with the MQL system, with the number expected to increase annually. Willy adds: "The excellent collaboration between MAPAL Indonesia and our engineers led to an innovation where MQL technology and PCD cutting tools were combined on the BT30 CNC machine. This has significantly increased productivity and reduced production costs, thereby improving our company's competitiveness. We are very grateful to MAPAL Indonesia for their excellent service and support and look forward to continuing our long-standing collaboration and cooperation to further innovate our tool systems and tool management."
MAPAL Indonesia is the official distribution partner of DropsA
Meanwhile, MAPAL Indonesia is the official distribution partner of DropsA and can thus offer complete manufacturing solutions with MMS devices and the appropriate tools. A corresponding agreement was signed at AMB 2024 at the MAPAL booth. Andreas Wasisto hopes for further dissemination of MMS technology in Indonesia. DropsA and MAPAL are already discussing transferring the Indonesian model to other countries.
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