REPORTAGE - R. MÜLLER CNC-FERTIGUNGSTECHNIK
The automation factor In 2016, Roland Müller, founder and owner of R. Müller CNC-Fertigungstechnik e.K. in Neuhaus am Rennweg (Thuringia, Germany) 2016 was facing the question as to whether he should slowly arrange for his retirement – or whether he should hit the ground running. He opted for the latter and got EROWA on board. After he had finished his training and obtained his master’s certificate, the born and bred Baden-Württemberg engineer started his business by building machines to customers’ specifications. In 2000, he set up his own business, which grew fast. Its focus was on precision parts, milled and turned parts, as well as on special machine and prototype building. Once he had decided to carry on, Roland Müller had a completely new production hall built in the immediate vicinity of the existing works. He now had sufficient space.
Industry 4.0 The entrepreneur was also aware of the fact, however, that if he really wanted to “hit the ground running”, he had to move in the direction of Industry 4.0. He collected extensive information about suppliers which would be able to support him along the way. He had already cooperated with EROWA in a spirit of partnership for many years since he had relied on EROWA clamping equipment virtually from the very start. For milling machines, he opted for DMG Mori; in terms of measurement, he had confidence in the competence of ZEISS; and he placed process control entirely in CERTA’s hands. Since this latter was a subsidiary of EROWA, it was also clear with whom the company wanted to set off into the future: with the order, Roland Müller entrusted the entire project management to EROWA, which in turn guided the partners ZEISS, DMG Mori and CERTA. Off we go And this worked out excellently; Roland Müller was impressed by the partners’ reliable and problem-free cooperation. The new line automation was put into operation in early 2018. After a mere four months, capacity was again increased: EROWA successfully integrated a fourth DMG Mori DMU 60 eVo into the line. The extended plant became operational in late August 2018, according to schedule.
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REPORTAGE - R. MÜLLER CNC-FERTIGUNGSTECHNIK
Flexibility proves useful This arrangement creates sufficient leeway for the company to be able to react to customers’ individual requirements very fast, since the process control system controls the EROWA Robot in the background, and operators are able to react to short-term or particularly urgent orders at any time. The possibility to deliver flexibly at customers’ individual intervals and in customized batch sizes is of great significance for the company. It’s thanks to this just-in-time production and delivery that customers do not need to reserve any storage space.
The magazine The workpieces to be machined are set up outside the line. The order is transmitted to the EROWA JMS 4.0 process control system by means of an RFID chip that is located on the EROWA workpiece carrier. Subsequently, the workpiece is added to the manufacturing line through a loading station. The EROWA Robot Dynamic ERD 150 Linear then transports it to a free magazine position. The magazine plays an important role in the line, since the workpiece finds a free position after each work step, and the Robot “knows” where it is at any point in time. In all, 255 magazine positions are available.
Washing, quality, tool data After being milled on one of the four DMG Mori DMU 60 eVo centers, the workpiece automatically returns to the magazine and from there to the washing station. Finally, it is transferred to the ZEISS CenterMax for measurement. Here, all the manufactured workpieces are subjected to a 100% examination, for universal quality control is crucial to R. Müller Fertigungstechnik. Tool management, however, also experienced another important step ahead. The intelligent tool management method that is integrated in the process control system made the entire process a great deal more secure and transparent. The tool data that comes from the CAM system are directly filed in the CERTA ToolManagement and automatically synchronized with the machine.
Universally automated The Zoller presetting station was also linked up with the process control system. Thus, the geometrical data and the downtimes of any tool are available at all times. If a tool breaks, an identical sister tool will automatically replace it – which means that a milling process without interruptions has become reality. Since the lifetime of tools is monitored, operators learn early on when a tool has reached the end of its lifecycle. Thus, they are able to react in time, remove the tool from the center and replace it with a new one.
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REPORTAGE - R. MÜLLER CNC-FERTIGUNGSTECHNIK
Copyright © 2019 - EROWA AG R. Müller · CNC Fertigungstechnik e.K. Am Herrnberg 25 98724 Neuhaus/Rwg Tel: +49 (0) 3679 726804 www.cncmueller.de
24/7 When the new automation line became operational on time, Roland Müller was astonished: he had expected difficulties. But although adjustments were required here and there, the partners assisted the company with competent and expedient solutions at all times. Another important thing was to get the coworkers on board early on. Roland Müller rightly emphasizes that the best technology is useless unless the team is ready to exploit its advantages. For the company, these were the right and important steps into the future. The automation line enabled Roland Müller to increase flexibility and reduce machining times. With this high degree of automation, he is now capable of producing around the clock – 24 hours a day and seven days a week.
EROWA AG CH-6233 Büron Switzerland Tel: ++41 (0) 41 935 11 11 info@erowa.com www.erowa.com
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