Special delivery

Bob Love, Assistant Branch Manager at THK, examines the market forces behind the recent emergence of packaged linear motion solutions.

The world would be a very different place if we all had to source constituent components, no matter how small.

There would be little time for pastimes or hobbies.

Instead, we would liaise with innumerable suppliers, constantly require replacement parts and spend any remaining time putting it all together.

It would be relentless.

It sounds crazy, but in some sectors this behaviour is not only accepted, it's the norm.

In the field of linear motion, for example, OEMs and end users have typically specified linear motion units, motors, drives and control equipment from a number of distinct suppliers.

Until recently, this approach has been entirely understandable.

Linear motion guides provide the means by which the dynamics of machinery and components are achieved and positioned.

These mechanisms are installed in a host of manufacturing processes, from high-precision pharmaceutical and biotechnology environments to harsh industrial and process-orientated applications.

As a result, the significance levied upon them is considerable.

The conventional wisdom has been to source linear motion system components from separate, specialist companies.

Although this policy ensures that each element is designed specifically for an individual task, it also forces OEMs and end users to accept an additional level of responsibility.

For instance, time and resources are needed to design systems and subsystems and then source, assemble and test the components.

Additional couplings and mounting flanges are required, and knowledge of how to put it all together is obligatory.

Invariably, this commitment requires the talents of a team of skilled engineers, although this is becoming increasingly difficult to justify as pressure grows on manufacturers to cut costs and improve profit margins.

The OEM and machine retrofitter sectors have tolerated the additional costs of sourcing separate components from different suppliers because there hasn't traditionally been an alternative.

However, although demand remains constant, the onus is on component suppliers to offer solutions that will help customers drive down costs and reduce lead times.

With this in mind, some manufacturers are forming strategic alliances with complementary suppliers to create packaged, ready-to-install linear systems.

A number of components are used to operate linear motion guides.

For instance, the power that drives the guide is typically channelled through a stepper or servomotor.

Other elements include a power supply, encoder, drive and cabling, all of which have been typically sourced from specialist suppliers and manufacturers.

By bringing together these distinct components to form a pre-assembled solution, manufacturers can cut customers' costs and reduce lead times by removing key stages of the production process.

For instance, all-in-one systems effectively eliminate the sourcing, assembly and testing of various components from multiple suppliers, leaving OEMs to concentrate on maximising profits.

This commitment to change was recently illustrated in an ambitious strategic alliance between THK, Parker-Digiplan, Renishaw and HMK, which combined THK's KR actuator technology with Parker's DIN rail stepper system or a ViX servo drive.

Just as importantly, the resulting system also incorporated all of the required ancillary equipment, including an encoder, cabling and HMI unit, with dedicated programming support.

Like any fully integrated solution, the new KRE linear motion solution is ready to use, straight from the box.

This has clear and far-reaching implications for the end user.

Firstly, it means fewer suppliers are involved in the production process, which reduces the likelihood of late deliveries and missed production slots.

It also effectively abolishes the need for on-site component integration and testing, which shortens the time to achieve full production.

In addition, savings can be made during the initial design stage as machine builders are able to design a complete, functional unit, rather than an amalgam of parts, which in turn can simplify administration as there are fewer suppliers and less stockholding.

The advantages associated with ready-to-use systems are numerous and profound.

They reduce lead times and help customers drive down costs.

At a time when cost-cutting exercises prevail, these improvements couldn't have come at a better time.

Although the advantages of all-in-one systems are clear, the options open to OEM and machine retrofitters are numerous.

For example, packaged systems are increasingly offered by companies claiming to provide one-stop-shop solutions, rather than anything borne out of an alliance.

While this option retains many of the advantages outlined above, it fails to address the issue of specialisation.

In contrast, strategic partners can ensure their speciality is embodied within the solution by retaining responsibility for a specific aspect of the unit, thereby guaranteeing optimum performance and reliability.

For OEMs and/or end users, this shift away from separated linear motion products to amalgamated solutions can only reduce the burden of responsibility and increase production efficiencies.

Like JIT processes before it, the shift towards integrated solutions will undoubtedly enhance manufacturing processes and improve balance sheets.

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