One-of-a-kind service from MAPAL Indonesia

Astra Otoparts is one of Indonesia’s biggest automotive suppliers. Founded in 1976, the company’s clients are primarily numerous well-known automotive and bike manufacturers from Japan, South Korea and Europe. The group consists of 54 manufacturing and trading companies in total. One of these is Astra Otoparts’ Nusametal division, which manufactures components starting with aluminium die casting through to mechanical machining all the way to the finished product.

Like many other companies in the country, Astra Otoparts is faced with growing requirements for environmental action. The government is pushing industrial companies, particularly the automotive industry, towards “greener” production. This fits perfectly with Astra Otoparts’ image. The company has set itself apart time and again in recent years with environmental initiatives for causes such as clean water, reforestation and biodiversity. Species conservation efforts focused most recently on protecting the Javan gibbon.
 

Strengere Umweltauflagen waren für Astra Otoparts‘ Geschäftsbereich Nusametal allerdings nicht der einzige Grund, sich Gedanken über die Produktion der Zukunft zu machen. Wie die Firmenzentrale von Astra Otoparts befindet sich auch dieses Werk in Nordjakarta, einem der dichtest besiedelten Gebiete des Inselstaats. Das Unternehmen zwar Wachstum, dennoch bleibt der Bedarf nach effizienteren Prozessen mit besserer Qualität und erhöhter Produktionskapazität mit den vorhandenen Maschinen eine Herausforderung. Hier kam dann MAPAL ins Spiel. 

Die Niederlassung des Werkzeugherstellers war 2014 in Jakarta an den Start gegangen und bietet mit mehr als 20 Mitarbeitern das Produkt- und Leistungsportfolio inzwischen noch an drei weiteren Standorten auf Java an. Die Kunden kommen vor allem aus dem Automotive-Bereich, wobei in Indonesien die Hersteller von Motorrollern einen Schwerpunkt bilden. Oft unterstützt MAPAL Indonesien Maschinenhersteller auch in Projekten für Japan oder Indien. In Jakarta gemeinsam mit Automobilisten ausgearbeitete Lösungen wurden auch bereits auf Produktionsstätten in Taiwan, Vietnam und Thailand übertragen. 
 

Im Rahmen eines Seminars wurde Nusametal auf die MMS-Technologie aufmerksam. MAPAL zeigte dort den Einsatz von PKD-Werkzeugen mit Minimalmengenschmierung, was eine deutliche Verbesserung der Aluminiumbearbeitung versprach. Denn neben den bekannten Vorteilen der Bearbeitung mit MMS ergibt sich insbesondere bei der Feinbearbeitung von Aluminiumlegierungen eine bessere Oberflächengüte im Vergleich zur Bearbeitung mit konventioneller Kühlschmierung mit Emulsion. Gründe dafür sind die bessere Schmierwirkung der MMS-Medien und die Abwesenheit kleiner Partikel, die vom konventionellen Kühlschmiersystem nicht ausgefiltert werden.

Die Minimalmengenschmierung erfährt aber im Zeichen von Ressourcenschonung und Energieeffizienz seit einigen Jahren einen Boom in der Industrie. MAPAL bietet nahezu alle seiner Werkzeuge auch in Varianten für MMS an und kennzeichnet sie mit einer grünen Markierung. Bei diesen grünen Werkzeugen sind unter anderem die Kühlkanäle so modifiziert, dass eine optimale Zuführung des MMS-Mediums an die Schneiden und Führungsflächen der Werkzeuge gewährleistet ist.
 

At Astra Otoparts’ Nusametal division, the potential of the technology for the company’s own production was recognised immediately. The use of MQL would cut coolant costs, increase productivity, reduce the consumption of water and improve the condition of the production floor, which is rare on Java Island. Lower energy consumption also reduces the company’s own carbon footprint. Nusametal’s strong interest culminated in a joint project with MAPAL Indonesia aimed at re-tooling existing machinery to MQL. The company DropsA was also involved as the MQL equipment manufacturer.

The fact that DropsA has no presence in Indonesia was initially a major stumbling block. After some consideration, MAPAL Indonesia ultimately took over the import and installation of the MQL equipment. Up until this point, the team in Jakarta had no experience whatsoever with minimum quantity lubrication. “We knew this would be a challenge, as we first of all had to get to know the device and acquire knowledge on its installation, use and repair”, says Andreas Wasisto, Managing Director of MAPAL Indonesia. At DropsA in Frickenhausen and Milan, employees of Nusametal and MAPAL Indonesia got to grips with the technology.
 

The pilot project was a success. Astra Otoparts’ Nusametal division initially used the re-tooled machines to manufacture crankcase covers for scooters made by a Japanese manufacturer. Every day, the company produces around 11,000 of these aluminium components on a total of 24 machines, which are configured in six production lines. The MAPAL tools are used for pre-machining and fine machining and are each equipped with several PCD cutting edges. Face milling cutters with exchangeable PCD inserts and PCD-tipped form cutters are also used. Drills and forming taps are made from solid carbide. In comparison to competitors’ tools, the machining time could be reduced by around 20 percent using the MAPAL tools.

Rachmad Basuki, Engineering Department Head at Astra Otoparts’ Nusametal division, states: “The collaboration between engineers from Astra Otoparts’ Nusametal division and MAPAL Indonesia has played a pivotal role in enhancing tool design and driving internal improvements at Astra Otoparts’ Nusametal division. This partnership has boosted overall production performance, showcasing the power of cross-functional engineering synergy. The advanced technologies and innovative solutions introduced through this collaboration have become a catalyst for further improvements across the production area. These include layout optimisation, automation initiatives, and the development of jigs and fixtures, among other enhancements. The use of PCD tools with MQL has led to faster machining times and thus higher output, improving daily production volume considerably.” 
 

Even more benefits of the switch to MQL were also evident in production. The workspace stays much cleaner. The components are dry after machining, which means the laborious washing process can be omitted. Longer tool life and the associated reduced machine downtime contribute to higher productivity and reduced tool costs.

“The MQL project at Astra Otoparts' Nusametal division is one of our company's most valuable projects “, underlines Mr. Willy, deputy Chief Operation Officer of Astra Otoparts’ Nusametal division, explaining that the implementation which began on the CVT Transmission Cover production line has since been further expanded to other production lines. Currently, 24 of 150 machines operate with the MQL system which is set to expand annually. Mr. Willy adds: “The excellent collaboration between MAPAL Indonesia and our engineers resulted in an innovation combining MQL technology and PCD cutting tools on the BT30 CNC machine. This has significantly increased productivity and reduced production costs, enhancing our company's competitive advantage. We are very grateful to MAPAL Indonesia for their excellent service and support, and we look to continuing our long-term cooperation and collaboration to innovate in our tooling systems and tooling management.”