ServicePlus GB en

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Technical Services & Spare Parts

Retrofits & Used Machinery

Smart Services

Service Contracts

EMAG ServicePlus

Table of Contents EMAG ServicePlus

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EMAG Group

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Service Network

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Technical Services » Service Hotline

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» Fitness Check

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» Inspection and Maintenance

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» Service Partnership

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» Workholding Equipment Service

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» Balancing

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» Geometry Set

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» Replacement Modules

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» Replacement of Safety Glass

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» Spindelfix

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Spare Parts

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Training courses

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Smart Services

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» E-Tuning

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» Developments

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» Production and Start-up Support

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» Process Optimization

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» Fingerprint

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» Remote Experts

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» Data Backup

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» Service 4.0 Solutions

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Service Contracts

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» Customized Service Concepts

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» Full Service

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Retrofits & Used Machinery

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» Retooling

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» Conversion Work

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» Retrofit

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» Modular Retrofits

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» Used Machinery

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» Renting

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EMAG ServicePlus EMAG ServicePlus offers you a variety of individually modifiable services, customized to suit your specific requirements – from training to preventative maintenance, and retrofits to permanently available original spare parts.

In order to provide the best options for our customers, we use state-of-the-art technology and continuously optimize our ServicePlus organization. For instance, we meticulously analyze all of our service calls, record important information provided and highlight their solution, then make these notes available to clients worldwide and continuously improve the relevant software components. We're committed to finding solutions for even the most complicated problems. We guarantee that

we will find the right solution for you, thanks to our highly trained service technicians and our commitment to offering the highest standard of service.

We plan, develop, operate, monitor, test, fit, inspect, maintain and repair. We reduce idle times, boost productivity, prevent wear and ensure that your investment has a long service life.

We detect and correct technical deviations at an early stage and notify you promptly when replacement parts are due.

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EMAG Group

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In recent years, the EMAG Group has been a defining presence in the machinery industry, both in Germany and around the world. Numerous developments, ideas, challenges, and most importantly, our staff, have paved the way here.

We are a reliable partner throughout the automotive industry and beyond. Whether in the oil field or aerospace industry, EMAG has proven itself to be a strong company, and the perfect partner for the implementation of complete process chains.

We've not only been able to establish ourselves with our unique manufacturing systems in the automotive sector, but we've also been able to expand into other markets. There is a wide range of technologies available under the EMAG Group umbrella. Due to this diversity, we are always able to offer our customers the best manufacturing systems for the production of precise metal components.

What motivates us is the drive to always provide our customers with the best manufacturing systems for the machining of precision metal parts. With this drive, we succeed in inspiring our customers each and every day. In addition, we are – and remain – your point of contact, employer and business partner for a successful future.

The Global Service Network EMAG has a global service network, which gives us the ability to provide you with the benefit of our global networking, speed and reliability.

EMAG is represented all over the world, ensuring our ability to immediately spring into action for you wherever you are.

Our global service network covers all continents and locations worldwide, guaranteeing that our highly skilled personnel are always available regardless of your location. Our service technicians have access to our global knowledge systems, allowing

them to perform their service work as quickly as possible. The expertise and motivation of our employees allows us to offer first-class customer service to all of our customers around the globe.

With their expertise, our qualified specialists are able to provide the highest level of efficiency, and guarantee that you will always have a competent partner by your side.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Service Hotline Our most important task is maintaining direct contact with our customers. You can contact our customer service department, free-of-charge, between 7:30Â am and 5:00Â pm on business days.

To assist with problems that do not occur during business hours, we also have a central support center, open around the clock, even on Sundays.

Problems can be solved quickly through this hotline. The service engineers use software that allows them to view the design data and the current machine settings on your machines. Any spare part that is needed immediately and is readily available will always be delivered or ready for pick-up within 24 hours, 7 days a week. In the case of more complex problems, direct connection to the machine control unit is achieved worldwide via our remote services (Remote Experts). This allows us to solve problems as quickly as possible.

Technical Hotline Our technical hotline records all inquiries and provides you with technical assistance in solving the problem – either by phone or remote diagnosis. After fault analysis and error definition, the service contract is transferred to the relevant service team, and monitored until it is successfully completed.

Service Center You can contact our service center at:

+ 49 7162 17-4300 + 49 7162 17-4970 service@emag.com

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Fitness Check Fitness Check – the incredibly cost-effective inspection package.

When workloads are at their maximum capacity, inspection times mean a loss in productivity. The perfect time for fitness checks is when productivity is not at its peak.

The offer: High security at low cost.

With the fitness check, the overall state of each registered ­machine is carefully assessed against a 70 point checklist.

Among other things, this list includes: »» cables, hoses and covers, »» tool carriers, »» machine geometry, »» and the control cabinet.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Inspection and Maintenance Maintaining the availability of the machines is the most 足important objective for keeping production going.

inspection report, which also includes a catalogue of measures and a quotation.

In order to avoid failures and to increase machine availability, we offer you the opportunity to ascertain the current state of the machine as part of an inspection. All the necessary 足reconditioning or modification measures are listed in an 足

Based on our experience, servicing should be completed at least once per year, in order to guarantee availability at any time. Well-maintained machines guarantee quality and 足trouble-free production.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Service Partnership EMAG offers customers a cooperative servicing concept.

The concept: The customer’s expertise and experience, supplemented with the detailed knowledge of the EMAG experts is key to greater efficiency and lower costs.

Condition-oriented servicing: Individually agreed upon servicing requirements according to the state and operational demands of the machine.

The customer’s input: Servicing tasks oriented towards the customer’s internal maintenance competence and the available resources are developed between the customer and EMAG.

The benefits: »» An optimum service plan developed through cooperation ­between the customer and EMAG »» Reduction in service costs due to the customer completing part of the work »» Training programs developed by EMAG allow the customer's service employees to be better informed and remain up to date regarding technical matters »» EMAG machine parts are only replaced when absolutely ­necessary, based on the condition and the load profile »» The experience of the EMAG specialists prevents the failure of expensive modules, thanks to the timely replacement of small parts (wipers and seals, etc.) »» Individual servicing intervals to match requirements based on up-to-date findings from previous servicing »» Improved efficiency, performance and consistent production ­quality thanks to greater availability and less unplanned downtime »» Constant participation in technological progress (components are always replaced with the newest variant available)

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Preventive Maintenance

Example:

Preventive servicing and maintenance allow you to keep your costs under control and to maintain consistently high availability.

Success through partnership!

With average servicing and repair costs amounting to ­ approx. EUR 2,000 (incl. material) for each servicing, added to the additional costs through production downtimes, the cost of preventive inspections is amortized, even if the system suffers only one fault less per year.

Joint inspection: Customer – EMAG Objective: Stock-taking

Evaluation of the inspection account Objective: »» Produce a joint plan of action – who, what, when? »» Produce a qualification overview »» Produce a training program »» Coordinate the scope of the peripheral systems

Share tasks according to the inspection plan

Jobs that the customer can complete today

Jobs that the customer can complete after training

Jobs that have to be c­ ompleted by EMAG

Jobs according to the mutually agreed checklist

Jobs according to the mutually agreed checklist:

Jobs according to the mutually agreed checklist:

»» Geometry check

»» Annual servicing check on complex modules

»» Module replacement »» Servicing cooling units

»» Checking the default geometry settings

»» Servicing the revolver

Verification using the protocol for “EMAG Servicing Module”

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Workholding Equipment Service Even clamping devices need regular servicing and reconditioning!

We offer clamping chuck servicing for all products from a single source.

Every production process chain is only as strong as its weakest link. Only when the clamping devices are functioning properly can efficient machine tools reach their full potential. Defective or worn-out clamping devices mean a loss in precision, holding power and rigidity, and can lead to fluctuations in quality and production downtimes.

»» Secure clamping for: -- optimum cutting processes -- the highest level of safety for both your employees and the machine »» Removal, cleaning, checking and servicing of clamping ­devices. In the case of all worn-out and spare parts, an invoice is always produced following consultation with the customer and provides an itemized statement of costs.

This ensures full cost transparency and the assurance of ­production using clamping devices in top condition. »» Lubrication of all lubrication points every 20 operating hours, and in the case of heavy soiling every eight operating hours »» Complete cleaning of the chuck including disassembly every 2,000-3,000 operating hours

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Balancing The rotation speed of modern machine tools has steadily increased in recent years, to achieve higher cutting performance and more economical manufacturing.

These increases have also increased the performance demand of the spindles, tools and carriers used. The increasing speeds mean the effects of machine imbalance are becoming more noticeable. This may result in vibrations, decreased workpiece quality and short tool service lives. On-site balancing of the clamping systems by measuring two different levels (dynamic balances) along with our highly dynamic spindles and their tools and mounts, help to ensure precise workpiece tolerances.

The benefits: »» Improved production reliability »» Improved workpieces »» Reduced wear on the spindle and therefore on tools »» Improved process reliability

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Geometry Set Geometry Set – all tools, measuring devices and special tools for checking the geometry after collision/tool breakage/­ maintenance/preventive measures are always within reach.

The maintenance of machines is essential in order to ensure high production quality standards and continued availability.

One of the most important tests relates to the geometry of the machinery. Due to geometric error, unacceptably high forces can act on the drive elements. This could lead to the premature failure of complex modules such as tool drives, slide guideways, feed drives or ball screws. The regular and preventive checking and restoration of tool carrier geometry, and the overall machine geometry, is one of the most important requirements for production without loss of quality, and for protection against consequential damages.

We created this geometry set for these check up's as well as for the recommended maintenance of the tool carrier and machine geometry.

The benefits: »» Higher machine availability through preventive measures to avoid component failures »» Fast maintenance after tool breakage and collision »» All necessary tools are on hand »» Reduction of maintenance costs as geometry can be adjusted and checked either as a preventive measure or in a timely manner »» The set price is 30% cheaper then the sum of the individual components »» Optional: EMAG service specialists can provide training for proper use of geometry sets

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Replacement Modules Instead of repairing individual module parts, we replace the ­entire module. Admittedly, the costs for the replacement ­module are initially higher, but overall you'll enjoy a cost ­savings due to reduced machinery downtimes and function-­ tested replacement modules.

The replacement modules concept covers the following: »» A complete replacement package for various EMAG ­machinery types »» All of the relevant mechanical modules, such as: -- Feed drives (all axes) – savings of up to 35% compared to new parts -- Spindle units – savings of between 35-50% when ­compared to new parts -- Cooling units, etc. – savings of up to 35% when compared to new parts -- Tool drives – savings of up to 25% when compared to new parts The replacement modules concept – don't repair, replace and save up to 50%.

Good value replacement modules are always available: »» Headstock units »» Revolver units »» Tool drives »» Feed drives

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Replacement of Safety Glass

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According to the German Machine Tool Builders’ Association and trade organizations, the safety glass on your turning or grinding machines must be replaced every ten years.

for the intended application. If you use only spare parts from the original manufacturer when making new purchases, the duration and reliability of the machine’s safety is guaranteed.

Particularly for turning and grinding machines, the danger present as a result of a high number of revolutions and violent centrifugal forces must not be underestimated. Our safety glass is fired at to test impact resistance and is checked especially

A stamp is inserted in your machine’s safety glass that provides information about the year of production. From this you can ascertain whether it is necessary to replace the safety glass.

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Spindelfix Spindelfix – now you can change clamping devices more quickly and easily.

For three changeovers per day and an average changeover time of 30 minutes, at an average hourly rate you save EUR 75:

When changing the clamping devices, the main spindle is locked mechanically (when the machine door is open) at the touch of a button using the Spindelfix element, and is ­monitored using a limit switch. Once the front door is closed and the automatic cycle has started, the locating assay is automatically unlocked.

»» EUR 9,000 for 120 hours per year »» EUR 750 for 10 hours per month »» EUR 187 for 2.5 hours per week With Spindelfix you save between 30% and 40% per changeover when compared with normal changeover times.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

≤ 24 hours Reaction time

24 / 7

Accessibility

≼ 95%

Availability of spare parts

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Original Spare Parts With EMAG original spare parts, you are not only investing in top quality, but also in excellent service and increased ­production security.

Take advantage of the reduced prices of many spare parts and rest assured that your production can continue with the level of quality you have come to expect thanks to OEM spare parts – and a spare part availability rate of 95% or more.

The EMAG service team is happy to give advice at all times and can provide the right spare part in the shortest possible time.

With EMAG, you receive everything from a single source: wear parts and repair parts, software, retrofit sets and much more.

Close collaboration with the Development Division ensures that original spare parts for all EMAG Group machines and production systems are constantly optimized and developed.

In the event, however, that repair work is required, you can completely depend on our engineers and on the fact that you are supplied exclusively with original spare parts at the most up-to-date development stage.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Training Courses A well trained and motivated work force is becoming more and more important in today's daily competitive environment.

Our EMAG training courses will provide a major boost to the education and motivation of your employees.

Our training courses provide participants with comprehensive knowledge on how to handle and work with our products. In addition, our machine and programming training courses also promote the understanding of interrelations, as well as independent work and target-oriented thinking.

Thanks to our experienced trainers, and our proven training ­format and methods, we ensure sustained and verifiable ­success for your company. These courses will provide both beginners and experts with new knowledge that will quickly pay off for your organization. You and your staff will see just how good EMAG manufacturing s­ ystems and equipment can be when you can use all of their functions and tricks to their full potential.

EMAG offers the following types of training: »» Basic and hands-on training courses »» Individual training »» Technology seminars

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Well-trained and competent employees are key in optimizing the system availability of machines and technology, as well as, to maintaining and improving a companies competitiveness.

We offer a comprehensive program that allows your e­ mployees to learn best practices for the functioning and application of your production system, guaranteeing its used to its full potential. Our courses are developed based on the practical experience of our specialists and the daily findings of our trainers, ensuring that your employees will notice a difference in their every day routine. We offer a variety of courses, so take a look at what we offer and select the appropriate training for your team.

EMAG TRAINING CENTER For more detailed information about our EMAG training offerings, please visit our website at www.emag.com

Your contact: Ms. Manuela Sijan + 49 7162 17-4904 training@emag.com

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

E-Tuning E-Tuning allows you to increase the availability of your ­machines and productivity, while reducing workpiece costs.

The cost of spare parts for older control units are often considerably higher than the cost of spare parts for newer electronics. The reason for this is that the components for older control units are typically only produced in small batches. With E-Tuning you can reduce the costs for electronic components and increase the productivity of your machines

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by updating and modernizing control units and other electronic components. This guarantees the maximum availability and productivity of your EMAG machines – and also means a ­significant reduction in costs for spare parts in the future.

Bring the electronics for your machines back up to date. ­Guarantee availability. Increase productivity. Reduce costs for spare parts.

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Practical Example: “Bottleneck Machines” Initial situation:

The advantages of this upgrade:

»» A production line with five machines produces 1,600 ­differential housings per day

»» Improvements in the bottleneck machine cycle times leads to an increase in line productivity of 12%

»» An investment of EUR 22,000 is made for upgrading ­components on two of the bottleneck machines in the line

»» There is an additional profit of EUR 6,720 per day as a result of 192 extra parts being produced at a rate of EUR 35. »» The customer receives additional spare parts at a value of EUR 12,000 for the remaining compound machines.

Calculation example:

Costs

Excellent value for money Start-up Spare part

New part

Spare part – old components

E-Tuning – state-of-the-art components

-- Higher prices for spare parts

++ State-of-the-art technology

-- No state-of-the-art ­technology

++ All-in service (installation and commissioning)

-- Reduced availability

++ Increased productivity

Investment

- EUR 22,000

New spare part stock

+ EUR 12,000

Profit from increased productivity in two days

+ EUR 13,440

Total after two days

= EUR

3,440

Surplus after covering investment costs

Result: Even after a short period of time, the investment of EUR 22,000 has already been amortized. The ROI is produced after just two days.

++ More innovation ++ Additional spare part stocks for other EMAG machines

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Developments

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Prototyping

Process development

The way towards the optimum machining solution begins as early as the preliminary stages with the definition and s­ election of the correct machine and the planning of the production process. Our team can help you ensure you make the right decisions with our range of consultancy services. We offer competent consultancy for all cutting machining t­ echnologies such as turning, milling, drilling and grinding, and also for “new” technologies relating to round and out-of-round workpieces. From the customer's workpiece, through the tooling, to optimizing the machining parameters and processes, EMAG has created a complete solution to solve any cutting tool problem.

Using the problems posed by our customers as the starting point, this service covers the combined development of new technologies, modules and even completely new p­ roduction systems, and can extend as far as assisting in series ­production. You will receive from us, customized solutions in which we account for all the operational, economic and legal requirements.

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Production and Start-up ­Support If required, we are happy to provide you with interim p­ roduction support. Our specialists will help you in setting up and adjusting the machines to the specific production conditions.

Simultaneously, your employees will be introduced to operating the machines through “learning by doing”. We are also happy to provide experts for a predetermined length of time in the event of staff shortages.

EMAG offers the following services: »» Production support in the start-up phase after commissioning »» Supplementary training and refresher courses during production »» Assistance in securing the production in critical project and restructuring phases, e.g.: -- For new workpieces and part families to be set up -- For supplementary machining processes -- Monitoring and optimization of changeover processes

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Process Optimization A company’s high productivity is the result of the optimum ­utilization of the available machines. Causes for losses in productivity often lie in non-reproducible production p­ rocesses, long retooling periods and poor utilization of available ­resources. This means that there is further potential that may be exploited.

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Our aim is to attain a significant increase in productivity within a reasonable timeframe. Optimizing the production steps creates potential for improvement, which immediately ­increases the production rate, allowing the investment made to be amortized in the shortest possible time. Taking your machine as a starting point, together, we will compile a list of technical possibilities for increasing your producitivity.

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Possible options for optimization: »» Reducing the non-productive times with software ­adjustments »» Updating the control supplier’s software and hardware »» Optimizing retrofit procedures »» Optimizing the cutting data by using new tools, cutters, etc.

Before process optimization: EMAG experts analyze your ­manufacturing system. This analysis allows us to determine the best ways to optimize your ­manufacturing process.

Working with your production engineers, we first consider the choice of the various measures, and analyze the possibilities for your manufacturing system. When looking at optimization ­options, we often consider your desired batch size. We are ­happy to advise you on any type of production – be it small series or mass production.

Next, we'll show you how to economically improve your entire system and how you can optimize your workpiece costs.

Optimization of long ­retooling periods

After process optimization: ++ Increase in productivity

Use of existing potential

Use of new tools/cutters

++ Optimization of work flow ++ Increase in quantities ++ Reduction of the a­ mortization ­period for your overall ­investment ++ Shorter retooling times ++ Reduction in idle times ++ Improved machine utilization

Updating software and hardware

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Fingerprint

The benefits:

Fingerprint allows you to increase the availability of your ­machines and productivity, leading to a reduction in workpiece costs.

»» Higher machine availability through condition-oriented servicing

An accurate diagnosis on the condition of the machine tool axes is usually made based on gut instinct or on the results of time consuming, difficult to obtain measurements. Often, exact data for preventive maintenance is not available, or can only be collected at high costs. This uncertainty makes it difficult to plan maintenance, and nearly impossible to change ­components depending on their condition.

Using Fingerprint, EMAG Service produces a diagnosis that provides information on the condition of the mechanical ­components. The best part is that no expensive dismantling or ­assembly work is required in order to perform a machine evaluation. Using the data provided by Fingerprint, you obtain an up-to-date machine status report.

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»» A longer service life for the machine »» Planned machine downtime for maintenance, prevention of unplanned machine failures »» Verifiable results with distinct characteristics »» The results are precise and comparable »» Machine history reports available »» The replacement of “incorrect parts” is avoided with precise analysis

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Using 3D acceleration and vibration sensors, the movements of the axes are analyzed and graphically represented. By analyzing the reports, you obtain reliable data relating to the condition of the machines mechanical modules and components.

Detect the current condition of the machine

Act proactively instead of reactively

Compare

The reference data for the fingerprint is obtained from the EMAG

With Fingerprint, you can quickly and accurately analyze the current

database. Subsequently, this fingerprint is also used as a reference for

condition of the machine. With this information, time and cost-saving

inspection and fault analysis.

maintenance can be performed based on the actual condition of the machine. »» The machines condition is detected very quickly »» Complicated disassembly and assembly for analysis is not necessary.

Increase the effectiveness of your maintenance! With Fingerprint, you can find out the current status of the machine, and quickly and accurately plan pending service assignments.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Remote Experts

The benefits:

Fast and secure expert help in the event of a fault.

»» Link to the machine via a secure online connection (EMAG VPN)

Remote Experts offers you a real alternative to time-­consuming and expensive on-site service. This service allows you to efficiently improve your machine availability and decrease your overall maintenance costs by giving you access to EMAG’s ­professional expertise at the touch of a button. Remote Experts begins with the constant recording of operational data and faults. Data from the recording will be compiled and given to you in the form of a report every quarter so you know exactly how your machine is performing. In the worst-case scenario, just press the “Call Assistance” button to ensure that you get EMAG’s ­extensive expert support.

»» “Call Assistance” button: Immediate contact with the EMAG Service Division for fault protocol assistance »» Online support worldwide and access to EMAG experts and their know-how »» Reliable definition of required spare parts and assistance in the order of spare parts »» 24/7 telephone support via the service hotline »» 24/7 spare part service in connection with the 24/7 service hotline »» Reduced deployment of on site technicians »» Minimized costs for failure, maintenance and repair

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Since 2010 we have been offering you, as a standard for each new EMAG machine, the new generation of our online services: Remote Experts. With this service-on-demand package, you have at your disposal the most efficient means of detecting and rectifying faults, as well as rapid expert help in the event of a fault.

The expert link includes a secure online connection (EMAG VPN) between the machine and a corresponding service staff member at EMAG. Connections are generally possible via (W) LAN or on a mobile device. The EMAG VPN connection is ­

always established between the machine and the EMAG server.

Here, the control computer and the control unit hard drive are linked, making data transfer possible, but only if the operator has activated the software! Only after activation can a secure connection between the machine and the EMAG Operator be established, making it accessible to our customer service personnel.

You can also find out about our cost-effective retrofitting ­packages from your EMAG customer service advisor.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Our fixed-rate services: »» Machinery or component identification »» Consultation on updating inquiries, including provision of a quotation »» Complete backup of machine data »» Installation of the storage medium and re-commissioning »» For archiving data, we will provide you with a complete backup of the machine data at the time of retrofitting

Data Backup Increase the availability of your systems by replacing hard drives that are vulnerable to wear and tear with new, wear-free data storage media.

If the control unit internal hard drive fails, this leads to ­unnecessary loss of data and can often lead to long machine downtimes. As an alternative to these hard drives, flash drive modules are now available as a substitute.

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The benefits compared with a hard drive: »» Long-term availability »» Obvious cost savings »» Not susceptible to vibrations »» Wear-free, meaning a longer service life Following retrofitting, the system will once again be in an operationally ready state with a one-year warranty on the replacement components. To allow you to archive the data, we will provide you with a complete backup of the machine data at the time of retrofitting.

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Service 4.0 Solutions

The benefits:

This is the start of a new era for your machinery. In order to continue to be a company you want to partner with, the EMAG Group is rolling out a plethora of cutting-edge products. These products include many innovative, new service solutions.

Would you like to know in advance which components in your machinery may malfunction, and which should be maintained?

»» More transparency

Do you want the ability to create a timeline of when machinery parts should be replaced? Would you like to be informed about the degree of utilization and productivity of your machine?

With these advancements, we can provide the right solutions for your production requirements, sometimes before you even know you need them.

»» Increased machine availability »» Proactive maintenance and servicing »» More direct, faster access to EMAG experts if servicing is required »» Intelligent production solutions »» Virtual machine and simulation of material flow »» Service apps and online portal (in preparation)

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Customized Service Concepts

The benefits:

Our service contracts are tailored to the needs of our ­customers. To determine the specific service needs of a facility, EMAG Service engineers perform a needs analysis at the ­customer’s facility. After determining the needs, EMAG S­ ervice bundles the necessary services into a customized package.

»» Reduction of unplanned downtime »» Optimum machine availability »» Simplified administrative processes »» Ability to plan service costs for the duration of the package »» Sustainable improvement and safeguarding of production quality and productivity »» Maximum accessibility and the most qualified engineers

Feel free to contact us – we would be happy to work with you to create a customized EMAG Service Concept that ­perfectly fits your production requirements. When creating your ­customized plan, we take into account all your operational, economic and logistical interests, as well as those relating to production technology.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Full Service With Full Service coverage, we develop a comprehensive plan that includes all individual service concepts that fit with your specific requirements.

We are also happy to perform each and every service ­intervention for you.

Here, we take into account all the operational, economic and logistical interests as well as those relating to production technology. Depending on the nature and scope of the service contract provisions, we can also guarantee the availability of the machinery.

»» Troubleshooting at any time, day or night (24/7)

Including all desired ancillary services: »» Inspections and preventive, condition-based maintenance »» Spare parts supply »» Remote services »» System monitoring »» Additional services available on demand All from a single source, at a fair price.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Retooling Regular changes to end products are more common these days.

This means being able to adapt to new production series or the production of completely new part families is necessary.

Thanks to our many years of experience, we can perform the desired changes to existing part families, and also proactively plan for new workpieces, as well as set up the equipment in preparation for these.

EMAG performs all requested processes, such as: »» Technical consultation

»» Production of the necessary test sheets

»» Provision and procurement of clamping devices, tools and measuring devices

»» Setting up the new parts until they reach process capability (Cpk)

»» Production of tooling plans and parts programs

»» Production support during the start-up phase »» Optimizing productivity during the start-up phase

You have a new workpiece or parts family. Your EMAG machine must be quickly converted or adapted for this.

Training of your employees for production and production support

Setting up new parts

Project planning

OUR RANGE OF SERVICES:

Assembly and installation on-site, or at EMAG

Creation of the NC programs

Procurement of required automation components 36

Process design and procurement of the required tools and clamping devices

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Conversion Work A second service life for your EMAG machine tool.

In order to be able to survive global competition, manufacturing facilities must be continuously updated. Funds and time for new machinery are not always available.

We can offer you the following packages up to and including individual conversion: »» Conversion planning »» Production of tooling plans »» Procurement of the required tools and clamping devices »» Creation of the NC programs »» Procurement of required automation components such as pallets, changers, stores, etc. »» Replacement of the feed drives (mechanical) »» Assembly and installation »» Setting up new parts »» Training of your employees for production »» Replacement of guides and drive units

Reconditioning your used machinery has the following ­advantages: »» Assurance of availability »» Extension of the life cycle »» Maintaining competitiveness

The economic alternative The profitability and productiveness of machine tools are decisive factors in their competitiveness. The economic and technical factors involved in reconditioning your machines: »» No additional investment needed for -- Tools -- Fixtures -- Foundations -- Power supply »» With OEM warranty

»» Replacement of spindle units »» Modernization of e-containers »» Upgrading of CNC controls (software + hardware) »» Overhaul and design of automation systems »» Individual conversion tailored to the customer’s wishes

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Retrofit The profitability and productiveness of machine tools are ­decisive factors in their competitiveness. As an economic ­alternative to purchasing new machines, we provide c­ ompletely and partially reconditioned machines from the Group second hand. Retrofitted machines are high-quality machines that allow recycled and refurbished components to keep machining quality high, regardless of age. These recycled components include a main body made out of M ­ INERALIT®, which is several years old, and the overhead slides made of cast iron. An additional benefit of retrofitting is that it's very environmentally friendly due to the fact that the parts that typically use the most energy to create are recycled.

The retrofitting machines do not just get a new look; the mechanics and geometry of the machine are also reconditioned.

The electrical, hydraulics and cooling lubricant supply are ­

completely refurbished or replaced. Everything throughout the retrofit process is completed based on the customers wishes, from partial to complete retrofitting, conversion and ­modernization of the control units and mechanical parts.

The economic and technical factors involved in reconditioning your machines: »» A familiar setup for the operator »» No additional investment needed for -- Tools -- Fixtures -- Foundations -- Power supply »» With OEM warranty

After

Before

Complete retrofit including new turret and new safety guard Result: Machine VSC 200 (built in: 1993) with approx. 43,000 operating hours

A similar acceptance process compared to a new machine

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Workpiece quality is the same as it would be with a new machine

Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Modular Retrofit Design your retrofit machine to fit your process requirements while also staying within your budget.

This program includes six modules that build on one another and can be implemented either individually or in stages.

MODULE 3 Reconditioning of machine tool spindle units MODULE 4 Reconditioning of the spindle units and tool carrier systems

MODULE 1

MODULE 5

Replacement of the feed drives (mechanical)

Improve energy efficiency with modernization of the energy container and installation of the latest drive control technology including the software environment - to enable all energy-saving features

MODULE 2 Replacement of the feed drives and guide rails (mechanical), including new geometric protocol

MODULE 6 Individual retrofit according to your needs and requirements

Thanks to the modular design of the EMAG retrofit program, you can reap the full benefit of your investment, and obtain a completely customized EMAG machine that is as good as new.

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Used Machinery

Our range of services:

In the used machinery sector, we are committed to giving our customers personalized and competent advice regarding their production and machinery needs. We would be happy to speak with you about the solutions we have available that would fit your individual needs.

»» Planning machine relocation »» Backup production and prototyping »» Design of technologies and processes, and the preparation of necessary documentation »» Setting up new workpieces in your production systems »» Production support »» Purchase and sale of used machinery

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Technical Services & Spare Parts | Smart Services | Service Contracts | Retrofits & Used Machinery

Renting EMAG offers new and used production machines for rent.

Set up, connected and ready for production – in the shortest possible time.

Our rental program is perfect for handling production peaks, downtimes between receiving new machines or continuing production while your machine is out for reconditioning or modification. From the standardized pick-up turning machine to the ­multifunctional production center, EMAG offers machines for the efficient production of precise metal parts.

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EMAG Service worldwide Main offices EMAG UK Ltd.

NODIER EMAG INDUSTRIE

Chestnut House, Kingswood Business Park

5 avenue de l'Europe

Holyhead Road, Albrighton

18150 La Guerche sur l'Aubois

Wolverhampton WV7 3AU

France

Great Britain

Phone: +33 248 771123

Phone: +44 1902 37609-0

E-mail: service.france@emag.com

E-mail: service.uk@emag.com

EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 E-mail: service.usa@emag.com

EMAG MEXICO Maquinaria EMAG Mexico S de RL de CV Av. Hercules 301 Nave 1 Poligono Empresarial Santa Rosa 76220 Santa Rosa Jauregui, Queretaro Mexico Phone: +52 442 291 1552 E-mail: service.mexico@emag.com

EMAG DO BRASIL

ZETA EMAG Srl

Edifício Neo Corporate Offices,

Sucursal en España

CJ 1503

Pasaje Arrahona, n° 18

Rua Enxovia, 472

Polígono Industrial Santiga

04711-030 São Paulo SP

08210 Barberà del Vallès (Barcelona)

Brazil

Spain

Phone: +55 11 942579184

Phone: +34 93 7195151

E-mail: service.brasil@emag.com

E-mail: service.espana@emag.com

EMAG Salach GmbH

EMAG OOO

Austrasse 24

ul. Akademika Chelomeya 3/2

73084 Salach

117630 Moscow

Germany

Russia

Phone: +49 7162 17-4300

Phone: +7 909 1592349

E-mail: service.salach@emag.com

E-mail: service.gus@emag.com

EMAG KOREA Ltd. Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong Jungwon-gu, Seongnam City Gyeonggi-do, 13207 South Korea Phone: +82 31 776-4415 E-mail: service.korea@emag.com

EMAG (China) Machinery Co., Ltd. Building A3 & B7 Cangneng Europe & America Technology Park No. 8 Loujiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 536 76019 E-mail: service.china@emag.com

ZETA EMAG Srl

EMAG INDIA Pvt. Ltd.

EMAG (Chongqing) Machinery Co., Ltd.

Viale Longarone 41/A

Technology Centre

No. 10th Lailong Road

20080 Zibido S.Giacomo (MI)

No. 17/G/46-3, Industrial Suburb

Yongchuan District

Italy

2nd Stage, Yeshwantpur

402160 Chongqing

Phone: +39 02 905942-63

Bengaluru – 560 022

China

E-mail: service.italia@emag.com

India

Phone: +86 536 76019

Phone: +91 80 42544425

E-mail: service.china@emag.com

E-mail: service.india@emag.com

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