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High-mix, low-volume (HMLV) shops need a system that handles frequent changeovers without losing uptime. Nextas Tech FMS is a flexible manufacturing system that ties together our zero-point workholding, in-house scheduling software, and turnkey line integration—designed so the hardware and the software come from the same engineering team.
What the System Is Built From
The system is built around four areas where we control the design and manufacturing in-house:
1. Proprietary FMS Software
Nextas Tech FMS runs on a custom-developed software system written in-house by our own software engineers. Off-the-shelf MES packages usually need heavy modification to handle a mixed-part shop; this one was built for that job from the start.
- Real-time capabilities: Includes production monitoring, intelligent scheduling, and data-driven analytics.
- Automatic adjustment: Switches between product variants or accommodates urgent orders without manual reconfiguration, cutting changeover time by up to 70%.
- Easy Integration: Open architecture allows easy integration with existing ERP or MES systems.
2. In-House High-Precision Zero-Point Clamping System
The FMS relies on our own zero-point clamping system as the standardized interface between machine, pallet, and fixture. Because we make the clamping hardware ourselves, we control the tolerances that matter most:
- Micron-level precision: Locks workpieces with ±0.005mm repeatability, so a part lands in the same position each time it returns to a machine.
- Self-centering design: Locates the pallet the same way every time, so there is no manual edge-finding or dial-indicating to get wrong.
- Rapid changeover: The pallet drops onto the receiver and clamps in one motion, so a workpiece swap takes well under a minute instead of a re-indicating routine.
3. Turnkey Production Line Development
Nextas Tech FMS is a fully integrated, turnkey solution from design to deployment. Nextas Tech manages the whole lifecycle: from the initial needs assessment and custom design through on-site installation, testing, and commissioning. One team owning the machines, fixtures, software, and automation means fewer hand-off gaps and less downtime during the switchover.
4. In-House Engineering Teams
Nextas Tech FMS is built by three in-house teams — mechanical design, electrical engineering, and software development — so one company owns the whole stack.
- Mechanical: Creates solid, space-efficient line layouts and custom fixtures.
- Electrical: Develops reliable wiring systems and integration with automation components.
- Software: Continuously optimizes the platform and addresses client feedback directly.
Case Study: 4-Machine Integrated Flexible Automation Line
To illustrate the real-world impact of Nextas Tech FMS, let’s look at a recent project: a 4-machine integrated flexible automation line designed and built by Nextas Tech for its own in-house manufacturing facility.
The Challenge: Nextas Tech in-house factory faced HMLV challenges—frequent product changes, tight quality requirements, and limited floor space. Manual processes led to long changeover times (up to 2 hours), inconsistent precision, and low machine utilization (65%).
The Solution: A fully integrated line using four CNC machines, automated material handling, and the Nextas Tech Zero-Point System.
- Zero-Point Integration: Workpieces mounted on pallets with zero-point adapters for quick, precise clamping.
- Automated Handling: A robotic arm, controlled by FMS software, transfers pallets between machines.
- Unified Control: Proprietary software coordinates operations, robot movements, and scheduling.
The Results:
- Changeover time: Down from roughly 2 hours to about 12 minutes per job change.
- Machine utilization: Rose from 65% to around 88%, mainly because pallet prep happens off-machine.
- Scrap rate: Dropped from 4.2% to 1.1% after removing manual re-indicating from the process.
- Throughput: More parts per shift—the team estimates around 55% more, though exact gains depend on part mix.
Aligning with Industry 4.0
The FMS software already collects production data from each machine and zero-point station—cycle counts, clamp confirmations, scheduling logs—so the information is there when you need to track OEE or troubleshoot a quality deviation.
If your shop later adds predictive maintenance tools or MES/ERP integration, the system’s open architecture can feed data into those platforms. The design intent is to start useful today and not block upgrades later.
