EROWA MAGAZIN EN 2023

Powerful Network

EROWA stands for state-of-the-art manufacturing technology in tool and die making as well as for production and precision mechanics. In the areas of clamping technology and automation, we are one of the world's leading companies.

Our primary goal is to increase productivity for our customers. We achieve this with around 550 dedicated employees, our global network of 11 subsidiaries, 22 agencies and worldwide customer service.

We are convinced that sustainable success can only be achieved by working together. That is why we at EROWA invest in strong partnerships. The power of this network generates dynamism, growth, innovation and competitiveness. Networking is also one of the central topics in production. Become part of Industry 4.0 with our "Flexible Manufacturing Concept".

In this issue of EROWA Magazine, discover how customers around the world benefit from a partnership with EROWA, what solutions we have in store for you, and how we can how we can shape the future together.

We will also be happy to let you marvel at the powerful network of trees on the "Wood Wide Web". Enjoy reading and good luck!

Powerful Network

Your EROWA team

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24 VENTURING INTO SOMETHING NEW MOTIVATES US!

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The future is automated

The Komax Group, which is based in Dierikon in the Swiss Canton of Lucerne, supplies products in the field of automated wire processing, as well as for testing wire assemblies. In their in-house production, they rely on automation and the highest degree of process reliability.

also reflected in its cooperation with EROWA. "The two Swiss companies share the conviction that constant innovation is the best solution to future requirements," explains Alois Bättig, EROWA Switzerland's sales director.

Absolute process reliability

The Komax Group's machines focus on processes such as measuring, cutting, stripping, contacting and taping wires, and assembling connector housings. Standard models and customer-specific plants such as wire strippers and fully automated crimpers are complemented by an extensive range of quality assurance modules and networking solutions for the safe and efficient production of wire assemblies. The Komax Group also produces systems for testing wire harnesses.

Automotive industry

The Komax Group generates around ¾ of its turnover from the automotive industry - and this industry is currently undergoing a monumental change: electromobility, digitalization and autonomous driving are megatrends and call for increasingly complex wiring solutions and thus for products supplied by Komax Group.

Through continuous development and close cooperation with its customers and partners, Komax Group strives to optimize and improve automated wire processing. This is

As a market and technology leader, Komax Group makes great demands on its own products - and therefore has an internal manufacturing. "This enables us to react quickly to constantly changing challenges, and by extending the product range, we keep producing new parts. But digitalization in the field of production also keeps confronting us with new tasks. We're convinced that here, automated production has great advantages: what we produce today, we process the following week, without any great storage costs," explains Christian Schärer, Director of Mechanical Manufacturing at Komax in Switzerland. This flexibility also means that production must run at 100%. "Process reliability has top priority with us. We can't afford to make mistakes. And here we've been relying on EROWA for decades - in a spirit of partnership and with a great deal of success," adds Schärer.

In 1998, Komax equipped the first milling machines with the EROWA UPC and ITS 148 workpiece handling systems; the first EROWA robot was commissioned in 2000. Since then, further handling devices have been added, such as the EROWA Robot Multi on a Mikron HSM 600 U, an EROWA Robot Compact on a Geibel and Hotz FS 640, as well as EROWA's process control system JMS 4.0 ProductionLine.

Requirements to be satisfied by the new production plant

In 2022, Komax finally took the first step to replace its obsolete Mikron plant. "We specified clear requirements to be satisfied by the new production cell, and our aim was to take over our experience and any advantages of the processes running on the existing plants in order to

Alois Bättig, Sales Director, EROWA Switzerland and Christian Schärer, Director of Mechanical Manufacturing, Komax Group Switzerland

"We're convinced that it'll only work digitally and with automation."

Christian Schärer, Director Mechanical Manufacturing, Komax Group Switzerland

integrate them into the new cell and to optimize them further":

• Production costs were to be cut by more than 10%.

• Machine capacity was to be boosted by 20%.

• Ultimately, a spindle time per machine of more than 6,000 hours per year was to be attained.

• The highest degree of process reliability must be guaranteed by the machine and the handling system.

• It must be possible for mixed loads of individually clamped workpieces for 5-axis machining and large pallets with multiple fixtures to be machined together and flexibly.

• Flexibility for planning between prototypes, individual parts, small and big batches must be increased.

• High base load through a fixed set-up of articles.

• Use of existing equipment such as tombstones and vises.

• Automation and workpiece clamping systems which satisfy these requirements.

The new plant

An investment was made in a Heller HF 3500 5-axis machining center and an EROWA Robot Dynamic 500 Linear (on a 9-meter rail with 91 magazine positions). Machine pallets are changed with the robot, or via adapter pallets MTS 400 pallets and ITS 148 pallets. For the purposes of control and data transfer, the new production cell is supported by EROWA's JMS 4.0 process control system. Since the JMS 4.0 software was already in use on the Mikron milling machine and on a Geibel & Hotz for years, employees do not have any problems operating the process control system. Schärer adds. "The software helps us a great deal to organize all the manufacturing data and to keep them under control. Its operation is very intuitive."

The plant mainly processes steel and aluminum; existing production orders are continually reprogrammed and optimized. Batch sizes vary between 5 and 100 parts and part sizes range from 50 x 50 x 50mm to 300 x 250 x 110 mm. "Big workpieces and fixtures are mounted on MTS pallets. Smaller workpieces are palletized on the EROWA ITS 148 system. With the use of adapter plates, these workpiece carriers are universally integrated into the system. In this way, we keep resetting times to a minimum," says Schärer.

Increasing productivity at a very high quality level

After detailed planning and some adaptations dictated by existing spatial conditions, the new production plant was commissioned in late October 2022, and Komax is

well on the way to attain, and even surpass, the goal it set itself. Automation is ready for 24/7 operation.

"EROWA's tooling systems and the palletizing of workpieces make all the difference when it comes to guaranteeing and even optimizing flexibility in automation - in order to increase productivity and maintain Komax's very high quality standards," adds Schärer.

Mastering challenges together

The digital interlinkage of the entire production and the entire company constitutes a very great challenge.

"We're convinced that it'll only work digitally and with automation - but of course this is not always easy," says Christian Schärer. "Innovative and long-standing partners help us to find the right solutions to the individual challenges." Here, Komax profits from EROWA - and vice versa.

The future going forward

The expansion of the plant with a second Heller machine and an extension of the robot rail with additional magazine positions has been scheduled for October 2023. "We're already looking forward to the ERD 500 being utilized even better - after all, it's here to do some work," adds Schärer with a grin. For the future, however, it is clear that Komax will continue to invest in its own automatic production, for Christian Schärer is convinced that "the future is automated."

ERD 500 - THE FINAL EXPANSION

• ERD 500 with a transfer weight of 500kg

• Rail length: 14 m

• 2 loading stations

• 12 magazines

• 16 Heller machine pallets

• 34 MTS pallets 400 x 400

• 150 ITS 148 pallets

Made for big jobs

The "Giant Tooling System" (GTS) is the new, automatable tooling system innovation from EROWA. The patented system has been conceptualized to clamp large and heavy workpieces. Besides its use in rough machining, the tooling system is particularly suitable for rotative applications such as milling/ turning processes. The GTS can be mounted on every machine table and provides optimal machining performance, the highest degree of precision and uncompromising monitoring functions.

Process reliability & efficiency

With a clamping power of 80kN force per chuck, the Giant Tooling System constitute a stable and immovable machine table basis. The number of chucks can be perfectly fitted to customer requirements. The clamping status of the chuck and the workpiece is monitored by the hydraulic closed & open check with guaranteed reliability. In addition, the tooling system possesses a pneumatic cleaning function which protects all the relevant precision and function areas against contamination.

One particular feature of the EROWA Giant Tooling System is the "floating" clamping part. This unique feature provides thermal compensation, thus ensuring consistent quality and precision even in conditions of fluctuating temperatures, for instance during the machining process.

Additionally, a lowering & raising function that is integrated in the chuck allows for a loading/unloading process of pallets and workpieces that is easy on the system. Besides its manual application, the EROWA GTS can be fully automated with process reliability thanks to its extensive functions.

Made for big jobs

The EROWA Giant Tooling System is the optimal solution for companies that want to efficiently machine large and heavy workpieces to the highest quality standards. With its robust design and its technological refinement, the system is the best choice for demanding production environments.

There's no such thing, as no can do

Bihler production systems are 100% customer-specific, while great diversity in workpiece production determines daily activities. Because of this reason, Bihler needs flexible automation as well as versatile, fast, process-integrated and automated quality assurance.

High degree of parts mix, low volume

Since Otto Bihler developed the world's first automatic stamping and forming machine in1956, Otto Bihler Maschinenfabrik GmbH & Co. KG has evolved into the globally leading producer of special machines. No matter what stamped and bent parts or assemblies customers want to manufacture, Bihler combines a wide variety of processes such as punching, bending, welding, threading, screwing, assembling, etc. into fully automated complete solutions on its fully automated machines. For the production of machine components, Bihler processes workpieces made of steel, hard metals, plastics, special copper alloys and ceramics in part sizes ranging from a few millimetres to over 3 meters in length.

Once a Bihler customer, always a Bihler customer Bihler technology can be found in a wide variety of industrial sectors such as the automotive industry, the electrical and electronics industry, household technology and medical technology. The company generates approx. 40% of its turnover from the automotive industry. This broad diversification is a challenge but also constitutes Bihler's core competence. More than 1,100 employees and a worldwide service and distribution network take care of the often decades-long partnerships with customers.

This customer loyalty is the result of the highly individualized system designs. Almost all Bihler machines are unique, which means that many parts and components that are required are only produced once or twice and then never again. The machines are designed and manufactured precisely to meet customer requirements. "The resulting high degree of part diversity at a very low volume is one of the big challenges, not only for the design process, but also for automated production and quality assurance," explains Paul Höldrich, Production Manager at Otto Bihler. This is precisely the reason why Bihler relies on long-standing partnerships with suppliers and technology partners such as EROWA. "In this way we profit from each other and can continue our development together."

It was on the basis of this cooperation that the idea emerged to integrate an EROWA measuring machine into the manufacturing processes. "At Bihler, we've already been cooperating with EROWA since we started automating our machines in the 1990s - but to be honest, I wasn't aware at first that EROWA would also be able to provide the relevant solution in the field of automated measurement. But the overall package did more than convince us," explains Paul Höldrich.

Measuring made quick and easy

For Bihler it's essential that the measuring machine is integrated into ongoing workpiece production in order to make interim measurements on site, automated and without additional measuring programs. "And this without any great expense and as precisely as possible," adds Höldrich. "Process-integrated measuring and checking enables us to detect deviations from the required tolerances early on and to correct them during the production process." In this way, Bihler is able to supply the requisite quality and to minimize the reject rate since the parts can be rectified during the production

process. "It's this overall package precisely put together to satisfy our requirements that we found at EROWA: the EROWA CMM Qi quality measuring machine combined with the CMM CubeScan technology software and the accompanying automation solution," says the Production Manager.

EROWA's CubeScan technology

"That's precisely what we need - easy and quick measurements and checks without any additional programming and absolutely necessary specialist personnel," says an enthusiastic Höldrich. But one thing at a time: with the EROWA CubeScan software, you can non-contact measure the workpieces with the help of a laser scanner in next to no time. The only thing to be done in advance is to enter the actual dimensions of the workpiece into the template; after that, the measuring process will start automatically.

The superimposition of the scanned measured points with the CAD model results in a color mapping which reveals any errors straight away. The result is directly fed back into the JMS 4.0 process control system. Thanks to complete data automation, conclusions regarding quality and productivity can be drawn through JMS 4.0 at all

times. And one immense advantage is constituted by the fact that CubeScan measurements don't require any additional programming for a measuring program. Also, the CubeScan application enables operators to digitalize existing components quickly and without a great deal of work, i.e. to effect so-called reverse engineering. This is very helpful, particularly with components for which there in no digital data.

Expectations fulfilled

"This versatility and simple operation totally convinced us," says Paul Höldrich and measuring technician Manuel Schmölz enthusiastically. Direct measuring during component production allows for quick and uncomplicated corrections and minimizes the number of rejects and unidentified errors. This provides a further boost to quality while cutting unnecessary costs. Thanks to the CubeScan software, operators notice possible deviations from tolerances immediately. In the future, the measuring machine will also be fully integrated into automation in order to be even more completely incorporated into the manufacturing process.

"The overall package convinced us: super measuring machine, simple, quick and very versatile."

Paul Höldrich, Production Manager, Otto Bihler

Production measuring technology without any programming work

With the EROWA CMM CubeScan software option, workpiece dimensions are established by contact-free measurement with the help of a laser scanner in next to no time without operators having to draw up an additional measuring program for the purpose. The measurements are conducted automatically, the measured data are directly transferred into the controlling system and compared with the target dimensions. Measurements are thus made with as little work as possible - and with the most reliable output.

• Fast data analysis

Workpiece dimensions are established by contact-free measurement with the help of a laser scanner in next to no time. The result is directly transferred into the controlling system. Deficient workpieces are automatically blocked.

• No programming work

The CubeScan technology makes the preparation of a measuring program unnecessary, which enables you to conduct measurements with as little work as possible.

•

Simple application

Quick and easy - completely without any measurement specialists. Define the measuring area as a virtual cube with height, length and width - done. By overlaying the scanned measuring points with the CAD model, a colour mapping is created that makes discrepancies visible at first glance.

• Full control of the production process

Complete data automation enables operators to draw conclusions regarding quality and productivity through the controlling system at all times.

• Cost-efficient option

Every 3D coordinate measuring device from EROWA with the relevant accessories can be easily upgraded with the favorably priced additional software.

• Simple and quick digitalization of components

Existing components can be easily digitalized, which means that reverse engineering can be effected quickly and simply.

EROWA CMM CubeScan Technologyquick, simple and cost-effective quality control without any programming work.

The first step towards automated production

The small town of Landvetter is situated 15km east of Gothenburg, Sweden. Here RZ OLDA Innovation AB produces high-precision metal components. In late 2022, the company ventured on its first step toward automatic production, as Jan-Erik Svensson, CEO of RZ Olda Innovation AB, recounts.

EROWA: Mr Svensson, what does RZ OLDA Innovation do?

JAN-ERIK SVENSSON: We provide our customers with top-quality production solutions. Today, RZ OLDA Innovation consists of two parts, with one of them producing door fittings and the other being engaged in contract production, which accounts for the majority of the turnover. At present, contract production consists of 8 CNC milling machines (of which 3 are 5-axis) and 3 CNC lathes. Our production concentrates on milling and turning. This can be parts for the automotive industry, but also for the

tobacco or packaging industries. What all components have in common is that they've got to be precise and satisfy the highest quality standards."

What was the decisive factor that prompted you to make a move in the direction of automation now?

In autumn 2021, we almost had a "crisis meeting" since our production plant was hardly able to cope with incoming orders. We were thinking about how we could increase our capacity, primarily in our milling department. It soon became clear to us that we wanted 5-axis

machines with a certain form of automation. After some research, our attention was drawn to pallet changers that could be configured according to our requirements with a high mix of various parts in average batch sizes of 1-50 pcs, we must have a very flexible production process. When we came in contact with EROWA at a fair in Värnamo, we were immediately impressed by the simple and compact solution provided by the EROWA Robot Compact 80.

What precisely convinced you?

The speed of the whole thing, the short resetting times allowing for more machining time. But also the wealth of productivity in a very small space. The ERC 80 is easy to operate and has been integrated into our production without a hitch. It was precisely what we needed at that

point in time: a reliable, quick and simple automation solution that required very little space.

Does this mean that previously, RZ OLDA didn't work with either pallets or automation?

Yes, precisely, it was a big step for us. We first had to adapt our working processes to workpiece palletization and the automatic loading of the machines. But now, a year later, we're fully operational and the machines are running every day without any major problems. However, we must still learn how we can fully utilize our machines with the EROWA robots.

"Every change begins with a first step. We have dared to take this step, and we have invested."

Jan-Erik Svensson, CEO RZ OLDA INNOVATION AB

Anders Carlsson, Sales Manager EROWA, Jan-Erik Svensson, CEO RZ Olda Innovation AB and Lars Clarhav, Production technician RZ Olda Innovation AB

What does this mean specifically?

For us, this is a challenging process: we first want and must develop the knowledge and the technology of the new automated machine. Owing to our high degree of parts mix, we have to process many one-off parts. On top of this, we also have a lot of new orders, which we first have to program. This takes time and generates a great deal of initial work. Therefore the machines are still often standing idle. But thanks to automation, our employees will be able to concentrate much more on their "actual" work in the future - namely quick and precise 5-axis machining.

This sounds like a great deal of change?

Yes, it does, but all change starts with a first step. We dared to take that step and invest in it.

What precisely did you invest in?

As a first step, in new premises for the extension and development of our company. And in the course of this process also in two identical Mazak CV 500 5-axis milling machines with an EROWA Robot Compact 80 each. The configuration we chose consists of 10 320 x 320 mm UPC pallets and 20 ø 148 mm ITS pallets. In addition, we also use 148 P blank holders, which fit in well with our production. The UPC pallets enable us to handle just under 80% of all parts directly. The objective was always to grow. And this will only work with automation.

The conviction is there, so are your expectationshave they been satisfied so far?

Absolutely. We want more machining time, a more flexible production per machine, and all this with the highest degree of process reliability. These expectations have been more than satisfied - however, taking these steps is a challenge and a constant learning process for us. At the moment, everything is new: new premises, new personnel, a new CAD/CAM system, new automation, new machines and a new process control system.

Everything new - so everything better?

Definitely. We learn something new every day. We also notice that we can continually increase machining time and are also developing a certain status within the RZ Group, which we belong to. Complicated and high-precision parts are sent to us - mainly details that are smaller than 300x300mm and in volumes from 500 up to 1000 pcs to make it more profitable with the automation. We are pursuing or aim to grow step by step and optimize our processes on a daily basis.

Do you also get support from EROWA in this respect?

Absolutely. We're highly satisfied with the support we get, as well as with the automation and the tooling system. Thanks to the user-friendly interface of the JMS 4.0 process control system, a brief training period soon enabled us to control the machine and the robot comprehensively and integratively. We are able to prioritize our orders in a quick and uncomplicated way whenever necessary. In this way, we get the maximum out of the machine within the time available to us. And of course this puts us in a positive mood for further cooperation with EROWA in the future.

Thank you very much for the interview.

RZ OLDA INNOVATION AB

• Established in1985

• Integrated into the RZ Group in 2015 (16 companies in the south of Sweden)

• Parts volume between 1 and 100 parts for milling, average batch size of 500 for turning applications

• Part sizes of 10-20 mm up to 300 x 300 mm

• 20 employees

Efficient digitalization for the entire manufacturing process

Today's manufacturing industry is situated in a dynamic environment which calls for new and flexible answers. Challenges arise on a daily basis. Requirements with regard to quality and readiness for delivery are increasing. EROWA's solutions are modular and scalable: irrespective of different manufacturing processes, machine tools by all producers and from different generations can be integrated. With the JMS 4.0, EROWA offers a software package that was specially developed for data automation in production. With or without a loading robot.

The automation of the workshop starts with the automation of data. Flexible interfaces with upstream and downstream systems integrate manufacturing into the existing IT infrastructure. The imported data is passed on to the relevant production cells at the right time and in the correct format. Feedback from machines, (possible) robots or operators are recorded and centrally made available for evaluation. In this way, the entire process can be monitored and checked at all times.

Planning, controlling and monitoring the individual work steps

EROWA's JMS 4.0 process controlling system interlinks all the data and controls the entire manufacturing process. It automates the data flows from ERP and CAD/CAM to the production cells. JMS 4.0 assumes control of the

robots and of the data transmission and monitoring of the connected machines.

JMS 4.0 has a wide variety of interfaces with order and manufacturing planning systems such as ERP / PPS / CAD / CAM and others. In this way, data is imported automatically, and the current status of manufacturing is reported back in real time.

Whether for EDM or WEDM, for milling, drilling, turning, grinding or measuring: the JMS 4.0 software solutions link up machines of a wide variety of manufacturing technologies.

With EROWA's RFID-based EWIS system, the pallets and electrode holders are unequivocally identified. Thus, operators are always aware of the current position and status of workpieces and electrodes. The dashboard and supervision applications display the efficiency figures in real time, as well as the current status of the production cells. All this can also be viewed on the EROWA mobile app. Push notifications serve operators with warnings and alarms everywhere at all times.

The JMS 4.0 provides a simple and cost-efficient way of digitalizing and automating production, also without robots. The customer determine the degree of integration themselves - with or without automation, whether connected up to a single machine or integrated

throughout the workshop. The software is modular and can be extended according to requirements.

JMS 4.0

• Easy-to-view display of the entire production process

• Import / export interfaces

• 24/7 live machine status via monitoring app

• Transparent analysis of all manufacturing data

• Modular software components

• Intuitive user surface

Investing sensibly in the future

From a one-man show to an internationally operating company finding success through constant innovation and forward-looking technology. This is how Universal Laser Systems (ULS) developed into a market leader in the field of digital laser technology. Headquartered in Arizona, USA, ULS offers a wide range of customized laser systems from small desktop systems to large industrial systems for engraving, marking and cutting.

Challenge and Interest

ULS manufactures the components of its laser systems in-house. For reasonably priced modular components and for individual customer needs, ULS requires many single parts, small batches and prototypes. Aluminum alloys and INOX (stainless steel) are the materials mainly processed at ULS which has a high parts- but low volume-mix. This required a lot of setup and changeover time, resulting in a lot of machine downtime. There are approximately 750 part numbers with an average production run of 80 - 100 parts. ULS had standardized with fixtures to accommodate multiple part numbers to recover as much spindle time as possible.

Following their in-house guiding principle of constant innovation, Universal Laser System set a goal of producing more efficiently and doing so with flexible automation. Their own recipe for success of modular construction at a manageable cost was their basis in finding a suitable automation partner.

In September 2021, Nathan Zerkle, manufacturing engineer at ULS, first became aware of EROWA - a virtual tour of the company on YouTube featured tooling, workholding systems and automation. He was excited by the possibilities presented, so he contacted the company to learn more. Universal Laser System needed an automation system that was adaptable in workpiece scope and modular in expansion. They found that EROWA had the solution to meet their needs. Soon after, at two Haas UMC500 5-axis milling machines, an EROWA Robot Multi, the ITS148, PC210 workpiece holding and the JMS 4.0 process control system were installed.

Preparation during the day, production at night

All orders are now generated and processed via the JMS 4.0 process control system. All workpiece carrier pallets are identified via the EWIS chip system and transferred to the cell via the loading station of the Robot Multi using the "Setup and Loading Station Manager". Therefore, the cell manager always has an overview of all orderrelevant data and the productivity of the manufacturing cell - at any time.

With the EROWA Robot Multi automation solution, ULS can now produce continuously at night. During the day, small series are produced, and new orders and workpieces are set up and prepared for the unmanned shift on the appropriate clamping system. The result? Machine

efficiency has greatly increased, and setup times have been reduced.

ULS has not only automated its production, but also significantly optimized it. Existing processes were fundamentally rethought and adapted. Above all, the company wanted to reduce the multiple re-clamping of workpieces. This also led to creative optimization of the clamping devices in order to machine the workpieces on 5 sides in only one clamping operation, if possible.

Reduced workload for employees

The introduction of the robot enables the operation of a fully automated manufacturing cell, which also meant a process change in the workflow at ULS. Since fewer personnel are now needed to operate the entire cell, some employees were able to take on new tasks within the company.

The biggest challenge after installing the automated cell, however, was providing the system with enough

work to meet the cell's demand. Nathan Zerkle adds with a grin that they enjoy the luxury of this problem.

Experience with EROWA

EROWA has had a significant impact on ULS's manufacturing processes with tooling, automation, and process control system, exceeding their expectations. "The implementation and go-live of the cell was quick and smooth, and the after-sales support and training was exceptional," Zerkle said enthusiastically.

Nathan Zerkle's experience with EROWA highlights the benefits of automation solutions in manufacturing: Just one automated cell can drive productivity across the entire company. With this basis, the foundation has been laid to expand the cell modularly in the future - just as needed.

Automating self-centering vise with process reliability

In order to increase the efficiency of workpiece production, a safe and trouble-free automation solution is required. EROWA's "VPC" (Vise Power Clamp) clamping system has been developed for precisely this. Together with the suitable EROWA loading device, it guarantees absolutely reliable process automation.

VPC clamps everything

All workpiece vises with a pitch of 52 mm or 96 mm that are available on the market can be integrated into the EROWA VPC clamping system.

Choose between two system sizes

The VPC clamping system consists of two system sizes:

• VPC 52 chuck & chucking spigot for a 52 mm pitch.

• VPC 96 chuck & chucking spigot for a 96 mm pitch.

Performance and precision

The time-tested, functional and well-thoughtout clamping technology of the VPC chucks includes an integrated Z-support cleaning facility, status monitoring and a surrounding seal. VPC chucks can be fitted to the machine table directly or with a base plate.

Clamping with process reliability / automating without malfunctions

The VPC chucking spigots are made of high-grade hardened steel and have a long service life. The ground function surfaces ensure optimal insertion behavior into the VPC chuck. This results in clamping with process reliability and automation without malfunctions.

Easy and simple preparation

Preparation is simple: screw the VPC chucking spigot into the workpiece vise, the fixture or directly into the workpiece and tighten itdone!

Automation options

Automated loading substantially increases the number of productive hours on your machine tool. EROWA provides automation options to satisfy your requirements.

We'd be pleased to advise you with regard to your individual automation option.

Maximization of flexibility

Various system sizes can be adapted together and thus manufacturing flexibility can be maximized. With the help of adapter plates, the VPC clamping system can be flexibly integrated into the EROWA UPC (picture) and MTS systems.

Venturing into something new motivates us!

Being highly specialized and proud of producing sophisticated precision parts and assemblies for its customers: these are only two of the strong points of Wymed AG in Switzerland's Freienstein-Teufen. Its customers include renowned companies from medical technology, the semiconductor industry, watchmaking, as well as aerospace. In the field of orthopedic products, in particular, Wymed is a leading manufacturer of implants and instruments of the highest quality. As one of the first users, Wymed operates the new EROWA Vise Power Clamp (VPC) tooling system, and this is a fully automated production process.

and the continuing shortage of qualified staff. In order to master these challenges and to constantly optimize and even increase production quality and output with the existing personnel level, it's indispensable for us to run our machine tools automated and with complete process reliability," explains Michael Fallegger.

The (EROWA) solution

"Contact with EROWA was established in 2021 through DMG MORI," relates Bernhard Steiger, Key Account Manager at EROWA. He has served and accompanied Wymed since the start of its partnership with EROWA.

High demands

"We make high demands on ourselves and our manufacturing processes. The production of complex and sophisticated parts and the sourcing of new products motivate and challenge us. We provide customers with tailor-made solutions at the best possible price. And that's precisely where EROWA's products provide us with a great deal of support," explains Michael Fallegger, head of Wymed's CNC milling department.

Constant challenges

"Like the industry as a whole, Wymed is being confronted by the challenges of increasing material prices, the availability of raw materials, energy costs, digitalization

To optimize the existing production processes and to create capacity for new orders, Wymed decided to invest in suitable new milling machines plus periphery. After detailed researches, the company opted for DMP70 vertical milling machines from DMG MORI in combination with EROWA Robot Compact 80 robots. The compact design of the EROWA handling facility, in particular, was extremely helpful in the existing spatial conditions. Thus, two times two DMP70s with a Robot Compact 80 between them fit perfectly between the concrete pillars that stand in the production hall.

Recently, the DMP 70 machine tables have also been equipped with the EROWA VPC tooling system of system size 52. "And precisely this workpiece clamping system offers us so many advantages," explains Michael Fallegger. With the VPC clamping system as the precise interface between the machine and the workpiece, the workpiece holders in use can be automatically and very precisely positioned on the machine. The workpiece holders are equipped with four VPC chucking spigots. The ground functional surfaces of the chucking spigots ensure

integration behavior into the VPC chuck and thus trouble-free automation.

"This high degree of process reliability is essential for us. Without it we'd be losing hard cash. With regards to the validated production processes in the field of medical technology, we can't adapt production steps just like that. Automated production must simply run reliably and securely - and that's precisely what VPC ensures," adds Fallegger.

"It would not be possible to work as precisely and safely as we do now without the VPC clamping system."

Michael Fallegger, Head of CNC milling department Wymed.

Michael Bendel, Sales, DMG MORI Schweiz AG, Michael Fallegger, Head of CNC milling, Wymed AG and Bernhard Steiger, Key Account Manager EROWA AG

Stable clamping

Michael Fallegger lists numerous other advantages: "The entire system is very stable. Particularly when it comes to machining titanium, we notice how strong the four chucking spigots are. You can also hear it - it's less noisy. Also, the low-profile design leaves us more space for the parts to be machined, and we can integrate our existing equipment more easily. In summary, we must say that

working as precisely and reliably as we are now wouldn't be possible at all without the VPC clamping system."

The multi-flexible production cell

Michael Fallegger proudly presents the latest addition to the plant: a DMU 40 eVo by DMG MORI loaded by an EROWA Robot Compact 80 with an additional third magazine for more pallet capacity. Here again, the limited space was utilized to the max in order to boost productivity and extend the range of parts at the same time. The basis on the machine table is provided by the MTS with pitch 160 mm tooling system with air duct. The workpiece holders are integrated into the system with the MTS-VPC adapter pallets with pitches of 52 mm and 96 mm. This maximizes the part diversity on the DMU 40eVo to an extreme extent, for big and small parts can be processed in the same machine in automated mode.

Standardized process control system

The new machines and their handling facilities are directly controlled though the EROWA JMS 4.0 process control system, which is completely integrated in the production process. Fallegger emphasizes the importance of the JMS in operation: "The process control system is

very important for us; it controls the machines. It helps us administer all the accruing production data, plan orders and make production efficient. The software is intuitive and user-friendly; each of our employees has the app on his mobile and can therefore check the status of the machines at all times. It simply works - and that's what we want."

Successful cooperation for the future

Michael Fallegger is impressed by the modularity of EROWA's products: "The diversity of EROWA has convinced us. A great deal of automation on little space, with a highly modular structure, extendable at any time, and the highest degree of process reliability of the entire system - that's what we need. Our production is just as diverse as it is challenging, ranging from a thigh implant to miniscule workpieces of just a few millimeters." For 2025, Wymed AG is planning a significant extension of its capacity with a new building providing twice today's production surface in order to pave the way for future growth. "And there, we'll partner with EROWA again," which Michael Fallegger is looking forward to.

WYMED AG

Wymed AG is the result of the 2018 merger between Medic AG, which was established in 1946, and Wyrsch AG, which was founded in 1971. Since the end of 2020, Wymed AG has been part of the Hipp Technologie Group, which consists of Hipp Medical, Hipp Präzisionstechnik and Wymed. With almost 300 employees, they have been able to establish themselves as one of the leading partners in the DACH region for medical customers. According to their motto, "the customer develops and sells, we do the rest". Its fields of competence include the chip-cutting machining of high-alloy steels with adherence to the tightest tolerances, as well as assembly operations, including special in-house function checks. With 60 employees, a generously equipped plant, and thanks to certification in accordance with ISO 13485 (2016), Wymed AG is able to support its partners with an even higher degree of reliability. Continual investments in the company and accelerated automation have made larger numbers of parts perfectly feasible. Wymed mainly processes titanium, but also stainless steel, steel, cobalt, chromium and aluminum alloys and synthetics. The parts to be machined vary from just a few millimeters to 300mm in length with batch sizes from 50-10,000 parts and a diversity of up to 1,000 different parts per customer. The strongly increasing regulatory requirements can be efficiently complied with thanks to a healthy structure, lean processes and progressing digitalization.

Automation and high precision, par for the course for Prisme Méca

With its many years of experience, Prisme Méca sets the standard when it comes to machining complex, high-precision parts. Founded on know-how and an industrial vision focused on peak performance in production, the company headquartered in Le Grand-Lemps, a short distance from Grenoble, has experienced double-digit growth for over 25 years. With support from EROWA, the management board is introducing a flexible and competitive production system that is making it possible to achieve further performance gains.

pany, to offer our customers an increasingly competitive Industry 4.0 service," explains Jérôme Guignard, Head of Engineering at Prisme Méca and Managing Director of Triologic.

The company, established in 1998, was acquired in late 2021 by SAS Triologic and has since belonged to the corporate Group of the same name, along with the engineering office Mécanic 3D. With these three complementary companies, the management board has successfully set a course for external development aimed at continued growth and providing customers with an even more diverse and extensive range of products.

Automation as the cornerstone of a sustainable strategy

With more than seventy employees and fifty machines at the three locations, the Group is able to meet even the most demanding requirements of its customers - who are now diversified across numerous industries, such as medical, aviation and aerospace, military technology, and many more. "In order to support our customers' growth, we decided to invest in human and machine resources. This fits in perfectly with our strategy of fostering industrial expertise in our region while also growing our com -

The management of Prisme Méca opted for the solutions from EROWA particularly on account of this industrial vision, which is founded on continuous improvement and machine fleet automation. For a number of years, EROWA expert Dominique Ramousse has supported the company in its development and brought his analytical experience on board to propose the best tools for improving general productivity and increase the responsiveness and flexibility of the production facility. In the milling area, which includes numerous 5-axis machines from DMG, the ERC 80 Easy and Multi robots are already in use. With the associated tooling systems, the production site has continuously developed and improved its production capacities for milling complex parts. This is confirmed by Dominique Ramousse:

"Our robots adapt perfectly to any type of machine they are linked to. At Prisme Méca, the various 5-axis DMU 40 eVo and DMU 60 eVo machines were the starting point for our collaboration, and the selection of the associated robots was the subject of a special study aimed at attaining the optimal production organization." This decision turned out to be the right one for the management of the company based in Le Grand-Lemps. And when it came time for the latest investment, they of course once again turned to EROWA.

Gilles Chaffard, Managing Director EROWA France, Jérôme Guignard, Managing Director Triologic und Michel Rubio, Managing Director Prisme Méca

Improved reliability and level of service

When one of their biggest customers asked them to develop complex milled parts in the field of robotics, Jérôme Guignard and Michel Rubio quickly recognized the challenges of the project. Given the requirements and the expected volumes, the investment in a new robot-controlled production line was the logical choice to provide the customer with reliable and long-lasting services. Prisme Méca therefore invested in four 5-axis Mazak CV5-500 machines and one rail-guided ERD150L robot to serve all the machines. The robot continuously supplies all the machines from four magazines with up to 200 storage locations.

The new island with an investment value of EUR 1.3 million has been operating now for several weeks. Three new positions were also filled for the new production line. "Before the ERD150L was installed, our production facility was already operating in three shifts around the clock. But since the robot was put into operation, we have been able to optimize our service level while also rebalancing our staffing resources. Now, the previous night shift provides daytime support. The machines are now

running autonomously at night and on the weekends," notes Guignard enthusiastically.

The system was complemented by the EROWA JMS 4.0 ProductionLine software, which gives users an efficient, easy-to-use interface. The head of the Mazak division, Rémi Di Benedetto, who was hired to install this new line, agrees: "The machines are mostly programmed manually during the day, and at the end of the work day, the last operator present sets the four machines for automatic mode, so that they run all night and on the weekend. This way, we can produce up to 8,000 parts per week."

With this new system, Prisme Méca continues to grow, making production more reliable and guaranteeing customers a high level of responsiveness and competitive prices. With production excellence as a driving force and shared values, the partnership with the automation specialist is an undeniable advantage that will be further enhanced by the upcoming installation of more machines coupled with EROWA robots.

For large and heavy workpieces

The automatic and reliable loading of heavy workpieces onto machine tools makes certain demands on the handling system. Small series, mixed part sizes and varying machining technologies require flexible production systems. EROWA's LoadMaster Compact is the ideal automation system for transfer weights of up to 5,000kg. Conceptualized as a modular system, the LoadMaster Compact can be adapted to a customer's requirements and those of his production process. Thanks to the modular design, loading a single machine or a linkage of several machines does not present any difficulties. EROWA expert Alexander Winter explains the particulars of the system in a detailed interview.

INTERVIEWER: This sounds like a successful system, doesn't it, Mr Winter?

ALEXANDER WINTER: Indeed, we have achieved a very high degree of acceptance among our customers and in our markets with our LoadMaster system. It can really be described with three terms: fully developed, flexible and reliable.

Fully developed means that it has been developed to satisfy customer requirements in the course of many years, which in turn means that we're able to offer our customers a great deal of potential for the future.

Flexibility is also very much appreciated by our customers because we don't simply provide them with standardized solutions. We are also able to meet customers' requirements, such as spatial conditions, which is a big issue (a great deal of automation in restricted space).

The reliability we provide is also enormously important to our customers because after all they want to use such a system for production for years, if not decades. Here, for example, we only use best-of-class components. Also, further developments are thoroughly tested.

Alexander Winter, Sales & Key Account Manager EROWA LoadMaster Compact

Flexible and adaptable. With these orders of magnitude, safety factors undoubtedly play an even more important role. What's the situation in this respect?

ALEXANDER WINTER: Safety has first priority in production. The LoadMaster system offers various types of loading and unloading stations which guarantee a safe working environment. Here, safety and ergonomics are most important for operators.

Is the system restricted to certain machine types?

ALEXANDER WINTER: No, we're completely independent here. Various manufacturing processes and machine tools of all reputable producers can be integrated. EROWA's JMS 4.0 process control system controls the complete production process, automates the data flow and takes control of the robot, as well as data transmission and checks on the linked-up machines.

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