REPORTAGE - UNIVERSAL LASER SYSTEMS
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 inhouse. 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
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REPORTAGE - UNIVERSAL LASER SYSTEMS
Station Manager“. Therefore, the cell manager always has an overview of all order-relevant 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.
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REPORTAGE - UNIVERSAL LASER SYSTEMS
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