Turnkey solutions are gaining increasing importance in modern manufacturing. They represent holistic concepts where a solution provider takes full responsibility for the planning, implementation, and optimization of a manufacturing process.
It's not just about delivering individual components, but about the intelligent integration of machines, tools, fixtures, and digital services. A well-thought-out turnkey concept therefore offers customers maximum efficiency, minimal interfaces, and high investment security – especially in times of complex requirements and rising quality demands. As a full-service provider, MAPAL meets these criteria without exception.
Comprehensive competence under one roof
For Stephan Köstler, Senior Director Product & Service Management, the special strength of the MAPAL approach lies in integrating all critical disciplines: from process analysis to tool and fixture design to simulation, programming, and production support. The ability to take full responsibility for complete processes is a key differentiating feature. 'We don't just deliver components – we deliver functioning production,' he says.
The benefits for customers are clear: less organizational complexity, lower risk, and an accelerated production start. Industries with high quality requirements, demanding components, and tight tolerances particularly benefit – such as the automotive industry, including e-mobility, fluid technology, mechanical engineering, and aerospace. These are all key sectors for MAPAL.
Turnkey solutions quickly show their effects
Taking over process responsibility provides customers with planning security and forms the basis for informed investment decisions. MAPAL provides relevant return on investment metrics: significantly reduced ramp-up times, stable CPK values from day one, lower tool and process costs through optimally matched tools and cutting data, as well as clearly documented progress throughout all project phases. With reference projects, MAPAL can demonstrate how quickly turnkey solutions show their effects and economically pay off.
From project analysis to production ramp-up
MAPAL offers a comprehensive service package for complete machining processes – from feasibility studies to process design to series production. Already in the early project phase, optimal machining solutions are defined based on cycle time analyses and feasibility assessments.
Building on this, the design of the machining process is carried out with the most economical machining technology, as well as the provision of ready-to-use tools. Simulations, NC programming, and collision checks ensure high process stability even before actual use.
As a central element of every turnkey project, MAPAL develops and manufactures the appropriate clamping devices. The complete implementation – from design to production to the provision of ready-to-use solutions, including measurement and functional testing, collision consideration, and comprehensive technical documentation – is handled in one hand. The basis for this is in-house competencies and capacities in fixture construction.
MAPAL additionally relies on a complete 3D simulation chain. The fixture is digitally embedded in the real machine environment, all tools and NC programs are checked for collisions. Detailed reports, 3D visualizations, and close reviews with the customer ensure a smooth production ramp-up without surprises.
Digital further development of the turnkey approach
Looking to the future, MAPAL is expanding the turnkey approach with additional digital services. In the research initiatives PRODaaS (already completed) and PRODaaS@SCALE, efforts are being made to intelligently feed real process data back into planning. The goal: learnable, transparent, and even more efficient processes.
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