Interview with Mr Desislav Dimitrov, Director of Strategic Investment Projects at TESY
What FANUC equipment have you introduced in TESY production processes and what does it contribute to your operations?
We use FANUC equipment in our production facilities in two main areas: manufacturing plastic products and developing industrial robotic solutions. A few years ago, we purchased and commissioned two FANUC ROBOSHOT injection moulding machines to manufacture plastic components that we incorporate into our end products, namely hot water and domestic heating solutions. Before we purchased these machines, we had the opportunity to carry out tests with our mould tools at FANUC’s headquarters in Luxembourg. Following the excellent outcome of these tests, we invested in two FANUC ROBOSHOT α-S300 iA all-electric injection moulding machines with 350-tonne clamping force. After several years of operation, the results were far better than we expected and had previously planned on the basis of information from our discussions with FANUC. We have dramatically lowered our electricity consumption costs and increased production capacity from what we were obtaining previously with similar equipment.
The second main area where we work together with FANUC is industrial robotics. Our specialists have been through various levels of training to help them integrate robotic systems from FANUC, which makes us highly flexible and quick to implement projects within the production setting. Alongside support from colleagues at FANUC Bulgaria, we built our own ROBO centre, where the trained TESY team integrates various robotics and automation solutions. We also have a FANUC training unit that imparts system knowledge to our various specialists and operators.
What operations or processes have you automated using FANUC robots?
We have automated a large number of different operations using FANUC robots, such as welding, cutting, and a multitude of operations involving components and tools. Our focus in these processes is not to reduce staff, but to make the working environment more attractive for operators, make processes easier and, generally, increase operational efficiency.
What are the benefits of introducing robotics solutions in TESY production processes?
After introducing the robotic systems, we achieved both a stable single-stage production process and a much-improved working environment for operators, who were relieved of laborious, monotonous and unappealing work. Ultimately, robotic automation from FANUC has increased our productivity and reduced the cost of the products we manufacture.
Are you satisfied with the quality and reliability of the FANUC equipment you use?
At the moment, we mainly use industrial robots made by three manufacturers, which our trained staff operate and integrate into system solutions. We have been working in robotics with FANUC for 6-7 years and, so far, have not needed any service interventions due to breakdowns, despite running around the clock for 5 to 7 days a week. Fortunately, we mostly only need short stops for preventative maintenance routines.
To be honest, our specialists prefer FANUC equipment as this platform allows for the easy integration and adaptation of the hardware and software into our different solutions.
What FANUC Service Centre services do you use?
We use most of the services available from FANUC Service Centres. According to TESY company policy, all aspects of every production process must be safe and guaranteed. Equipment maintenance is one of the most important considerations in this area, which is why we rely on the preventive maintenance that our technical support teams plan and co-ordinate with the FANUC Service Centre. We are also very well harmonised with regard to software updates and installing additional system options and functions.
At TESY we have not made any warranty claims, which alone bears witness to the reliability of FANUC equipment.
What are your impressions of the FANUC maintenance workshop?
We work together to solve problems and organise processes, and have the full understanding and support of the FANUC team. So far there have not been any emergencies or unplanned shutdowns, which means that both the TESY and FANUC technical teams are doing an excellent job in terms of prevention.
We have no criticism concerning communication or response time. The FANUC team has fulfilled every service commitment in terms of planned scope and timing. Of course, we apply this explicit requirement to all suppliers and partners because any deviation affects the entire production process. We would like to thank the FANUC service team for their prompt and professional response.
Are you planning to implement other robotics solutions in your production processes?
We have integrated almost 30 industrial robots into our current production processes. The robotisation and automation process is fundamental for optimising our existing facilities and in the design of new ones. We are only at the beginning of this process and, moving forward, we plan more and more automation and robotisation. TESY is one of Europe's leaders in its field and it is only natural to partner with FANUC as one of the world’s leading robotics companies.