The Pilkington Automotive Deutschland GmbH plant in Witten is one of the largest automotive NSG Group sites in the world. Roof glass, windscreens, and rear windows are produced here for all European vehicle manufacturers. Integrated antenna systems are also developed in Witten and installed in the windows. A total of around 700 employees work at the Witten plant. The NSG Group is represented in Germany by the Architectural Glass and Automotive divisions and employs around 2,500 people. The site in Witten is part of the Automotive division with main production sites in 14 countries. The division is one of the world’s largest suppliers of glass and glass modules for automotive glass applications and supplies the Original Equipment (OE), Automotive Glass Replacement (AGR), and Specialized Transport (ST) sectors. Automotive OE offers complete glazing solutions, from initial design to final product, with a comprehensive range of glass products and glazing systems.

Continuity in Cooperation: Pilkington and NUM

In 2012, Pilkington and NUM carried out a successful modernization of a cutting system. This collaboration proved to be groundbreaking for the future of both companies.

Twelve years later, Pilkington returns to NUM to tackle another retrofit project. In this project, the mechanics remain unchanged, while the control system is to be completely renewed.

The ongoing collaboration between Pilkington and NUM demonstrates both companies’ commitment to continuous improvement and adaptation to the changing needs of the industry.

The Challenge of 24/7 Production

The upcoming modernization of a CNC machine poses a particular challenge for Pilkington, as its operation is uninterrupted. The machine to be modernized is responsible for cutting and grinding glass in various thicknesses, which is then used in roof glass, windscreens, and rear windows for leading vehicle manufacturers. Around one in five vehicles worldwide is fitted with Pilkington glass from the NSG Group, so continuous production is of the utmost importance to ensure the existing supply agreements are met with the usual high quality.

The requirements for the successful modernization of this machine were therefore extremely high and varied. Minimal downtime within a fixed schedule is required to minimize production downtime. In addition, the machine must be put back into operation quickly and efficiently after the conversion, which requires careful planning and coordination of all those involved in the project.

A Partnership for Smooth Processes

As part of the retrofit of the machine and system components, Pilkington successfully carried out a series of hardware adaptations. These included the construction of a new control cabinet in which the NUM CNC system and other components were fully installed and wired. In addition, mechanical modifications were made to the machine, including the assembly of the motors in the system and the installation of new protective grilles.

A detailed work plan was developed and coordinated to meet the high requirements in terms of time pressure and functional guarantee. This included the status of the machine, the pre-commissioning of the motors, the removal of the plant components during the summer vacation break, and the installation of the new motors by Pilkington. NUM then carried out the commissioning according to the specified schedule.

During commissioning, it was discovered that existing production programs needed to be converted. NUM reacted professionally and wrote a conversion tool on-site to ensure the continued use of existing programs. NUM also successfully merged two operator terminals, keeping the operation as identical as possible to minimize operator training.

The converted plant components were returned to the plant on schedule and within the machine availability period, and 24/7 shift operation was resumed. Pilkington was highly satisfied with the smooth integration of the converted plant components into production and the successful completion of the project. The collaboration between Pilkington and NUM has resulted in an efficient and timely redesign of our plant sections, optimizing production processes and improving plant performance.

The challenge for Pilkington was to ensure continuous production around the clock. The installation of new software with new hardware components and the subsequent guarantee of a smooth production process were decisive requirements. In this context, NUM demonstrated its expertise. Mr. Anthony Becker, Group Leader Technical Department, emphasizes: “Adherence to the schedule and trouble-free commissioning were of crucial importance. We considered this project as a pilot project with NUM to consider a possible conversion of further CNC machines.”

The commissioning went extremely smoothly. Mr. Becker emphasizes: “In the event of any obstacles, we received first-class support from NUM. The NUM team responded professionally and extremely quickly, so that we were able to start production again surprisingly quickly.”

Success Factors: Careful Planning and a Strong Partnership

Pilkington did not approach the planning of this venture lightly but was aware of the potential risks that could arise when involving external partners. Thanks to the short lines of communication with NUM and the maintenance of an excellent partnership, the project was successfully implemented. Mr. Ayhan Dikmen, Project Manager at Pilkington, emphasizes: “NUM proved to be extremely flexible in overcoming complex challenges and impressed us with their know-how and quick response, which gave us a high degree of security and reliability throughout the entire process.”

Increase in Production Output and Future Prospects

After minor faults were successfully rectified after commissioning, production continued to run smoothly without any disruptions. While the mechanics remained unchanged, the control system was renewed. By merging two operator terminals into one, machine operation was optimized, saving the operator the inconvenience of having to walk around. The quality remained consistently high, while the speed could be increased, and the CNC control proved to be more precise than before after the conversion. Pilkington’s CNC cutting and grinding machine currently produces around 6000-7000 individual panes a week for windshield production in the automotive industry.

Thanks to its professional approach, NUM always provided security during the conversion and smooth commissioning and was seen as a reliable partner. Mr. Dikmen emphasizes: “During the entire course of the project, the NUM team was able to guarantee security for a professional implementation. I was able to rely on their support and quick response at all times. Expectations were exceeded.”

Pilkington is planning to modernize further CNC machines with the NUM CNC control system in the coming years. This decision underlines Pilkington’s confidence in NUM’s expertise and innovative strength.