Integrity’s Manufacturing Execution System is designed to adapt, adjust & refine.

• Integrity is proud to showcase our latest 5-Axis champion in High-Speed, High-Accuracy Machining, DMU 340 Gantry.
• This highly dynamic machine offers improved quality and increased precision for massive work pieces.
• Ideal for cutting large tools including Fascias, Rockers and IPs.
• Impressively, it uses linear drive motion and a multi-purpose spindle to handle both 2D milling and finishing – thus reducing lead times substantially

• IMSA universal deep hole drilling and milling machine for small sized molds (1 meter and under)
• The MF1300BB-4P has 2 separate heads:
  • One gun drill head
  • One ISO50 milling head
• The gundrill head includes an automatic gundrill tool changer with 4 positions
• The milling head is served by an automatic ISO50 tool changer with 80 positions
• Also includes a work piece automatic pallet changer to manage parts up to 12 tons – 2 positions

• Coming this summer at Integrity HD
• New and innovative concept of bridge-type machine which combines traditional roughing capacity with the speed and precision of high performance machining
• It includes a unique system which controls the temperature generated in the vertical axis of the machine.
• Unlimited capacity and unique in that they include dual work zones as well very strong milling head

• Universal DHD and Milling Machine – cuts out wasted time
• 3 meter size travels
• Unique – first 20 drill capacity Gundrill changer
• Designed by moldmakers for moldmakers

• Coming this summer
• Compliment to our 3D comp cell
• Our custom application include are designed in one cell – 2 machines and a robot
• Includes Pallet Automation to reside between in support of both machines
• Built-in Intelligence – Hyper-i control and next generation power supply, providing the fastest machining speeds available today.
• HyperCut reduces cut times and the total number of machining passes while achieving superior surface finishes with exceptional part straightness and accuracy.
• Makino’s HS Rib, a new compact, high capacity, high speed head w/ core cooled ballscrew provides 1 G acceleration.

• 2nd machine – Coming Summer 2022
• EDNC21 machine is capable of achieving high positional and feature accuracy with fine surface finishes
  • Also has Hyper-i and Hyper-rib
  • Twin head machine configuration
• Independent programming and execution of different part features at the same time, which can significantly impact throughput for large tooling.
• Erowa Robot Dynamic (ERD) with 160 electrode capacity to feed both heads.
• Utilizes a stationary worktable design that positions the dual gantry-style heads over the work piece while supporting part weights up to 44,000 lbs. (20,000kg).

• New at Integrity’s Innovation Center and Integrity Tennessee
• 4 meter travel High-Speed Machining with next generation levels of precision for improved accuracy and surface finish
• Customized to include:
  • New Structure studies with advanced FEM system, more rigidity and thermal stability
  • Added the Machine body thermal stabilizing set to supervise the temperature of the various inner components liable to temp. variations
  • Added Precision 5 axis Compensation features in order to be always more precise on the final results

• Coming in 2023 – Integrity HD2
• Pallet changer for more efficient machining practices.
• Work pieces up to 26,400 lbs
• Tool lengths up to 35”
• HSK 100 tool spindle with 8,000 rpm and 1,327 ft lbs of torque
• All DMG Mori machines are C02 Neutral since January 2021.

• Integrity Tennessee is proud to announce our latest 6/7-Axis Multi-Functional Milling Center, Cheto IXN 2000, coming this fall.
• Offers the addition of an Extra Rotation, sophisticated Milling and also provides Deep Hole Drilling – resulting in significantly faster cutting times.
• The Cheto IXN 2000 can handle any range of tools
• Operational – February 2022

The Digital Twin/ IntegrityOS mission is to enable data based decision making to drive operational efficiency, quality and growth.

• The platform helps our processes be sustainable, repeatable and produce predictable results.
• Connecting and Centralizing all of our data, providing us with a single source of the truth.
• Applying AI on top of our single source of the truth will empower and enhance the decision making of our team not replace them.
• We are capturing more data points that will allow us to improve our workload projection, better understand the impact of potential or
  upcoming work and helps eliminate bottlenecks before they are a problem.
• Data points will also improve our ability to recognize and reward outstanding performance.
• We are building a better user experience for our team members in order to allow them to perform at a higher level.

IntegrityKB – Our knowledge base application is a customizable and searchable wiki style system comprised of our dynamic procedures, lesson s
learned and best practices

Plant Utilization View

Cell Utilization– Plant/Department/Cell

• Integrity uses a systematic approach to workpiece loading and unloading called Palletization. Robotic palletization is used in many of Integrity’s work cells – High-Speed machining, Universal Deep Hole Drilling and Milling, EDM to name a few.
• Robotic standardization gives a shop the ability to interchange work among various machine tools easily and efficiently:
  • Less Idle Spindle Time
  • Better Machinery ROI
  • Decreased Setup Time
  • Greater Productivity
  • Lower Labor Costs

• Integrity is committed to a system for organizing spaces so work can be performed efficiently, effectively, and safely.
• Lean Principals and 5S: Sort, Set in Order, Shine, Standardize, Sustain. Emphasis on safety
• When implemented correctly, maintained and refined – it makes everyone’s job easier.

OUTCOME: A cleaner, organized, safer, more efficient environment & reduced risk of errors

• Years ago, we considered combining all locations
• But the economic impact revealed an ineffective ROI
• By maximizing all locations (building/land) – we created a strategic/intelligent Moldmaking System to reduce production time:
  • Minimize motion
  • Improve quality
  • More room:
    • Organization
    • Future investments

Planning for a Total: 332,740 ft2 or 30,912 m2

• Refined Space following Integrity’s 6S principles
• Small and Medium Component manufacturing
  • Dedicated team/machines
  • Away from day to day production done concurrently
• Optic and high accuracy cnc machining
• EDM and Wire EDM capabilities
• Dedicated CNC training program
• Fabrication Department
• Research and Development with a dedicated CNC for testing processes
  and theories.

• Raw Material Saw cutting
• Eyebolt & Heavy Machining (EHD MES)
• Stress Relief and Metal Processing
• Flexible large 5-Axis Machining
• Ejector Box Manufacturing & Assembly
• Universal Turning Division (UTD MES)
• Mold 2D Component Manufacturing (2DCM MES)

Integrity’s Manufacturing Execution System is designed to adapt, adjust & refine:

• Dedicated area and dedicated team – Synergy 4
• High-Speed – High Accuracy – Better results Finishing
• Continuous 5 Axis
• Volume of Machines allows Integrity to easily Replicate process
• Run multiple jobs and packages at the same time, same results
• We added a 7th Kenichi High Speed Mill for extra capacity
• The systems can run 24/7 – lights out technology