Contents
02
A warm welcome
Industrial furniture production
Technical highlights
06
A warm welcome
14
Series production
42
laserTec
08
The HOMAG Group
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Batch size 1 production
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completeLine
32
Production of complex individual parts
46
Postforming process
48
combiLine
50
Material handling
52
Lightweight panels
10 Engineering
03
Software
lifeline l service
Convincing arguments
58 Simulation
66 Servicing
72
Resource efficiency
68 Financing
74
Quality assurance
60
Identification
62
Production control
76 References
04
A warm welcome The HOMAG Group 路 Engineering 05
06
Looking for independent professionals and perfect interaction at Looking for machines, the same time? but also networked logic operation?
You want the benefits of a team, but only a Then you have come single contact partner? to the right place! A warm welcome to the HOMAG Group.
A warm welcome 07
HOMAG Group AG Management Board Members
Storage, sawing, edge banding, drilling, hardware mounting, pressing, packaging – HOMAG Group offers precisely the solutions and systems you need specifically for your furniture production. No matter whether you are looking for a stand-alone machine, a production cell or a plant: The HOMAG Group offers you the choice of a broad-based product portfolio comprising hardwearing, modern machines and intelligent software.
Right from the start, you enjoy the support and backing of a fixed, specialized engineering team under the supervision of your contact partner, the project manager. Together you work to develop a solution which is precisely tailored to the needs of your company.
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Your success
The HOMAG Group: Specialists working as a team towards your success 09
HOMAG Group
The machines
• Internationally leading suppliers of machines for the woodworking industry • Worldwide the most extensive sales and servicing network for the woodworking industry: 21 self-owned companies, 60 exclusive partners, 150 independent dealers • Eleven highly specialized individual companies work hand in hand to ensure your success • Over 50 years of experience • Impressive references from renowned companies • Other producing locations, e.g. in Shanghai, São Paulo and Barcelona • Continuous growth through successful dynamic strategy
• Stable • Innovative • Highly specialized • Inter-coordinated • Use of many identical components • For processing panel-shaped workpieces • Compatible control systems • Standardized control system • As stand-alone machines, cells or complete plants • Modular design retrofittable, upgradable • Divided into performance categories for simple orientation
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Engineering 11
Solutions with added value
Project management
HOMAG Group offers greater efficiency and flexibility for your production. Our machine range is modular in structure and divided into price-performance categories. We work with you to design the right solution for your needs.
• Requirement analysis • Elaboration of a concept and target specification • Determination of performance characteristics, if required with the aid of simulation • Layout planning • Risk analysis • Scheduling, coordination, monitoring • Continuous cost estimation • Assembly • Commissioning • Monitoring/reporting • Comprehensive on-going advice • We are quickly on hand whenever you need us
The HOMAG Engineering project leaders develop custom-tailored solutions for the manufacture of your products. The HOMAG Group’s broad-based machine range and cooperation with experienced partners culminate in optimum processes which deliver impressive economic results. The international servicing network supports you in the operation of your machines and plants, and offers outstanding investment security over many years.
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Industrial furniture production Series production 路 Batch size 1 production 路 Complex individual parts 13
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Series production 15
Efficiency through series production
Production of today’s panel furniture is inconceivable without high-performance machines demonstrating the highest process reliability. The HOMAG Group offers precisely the right plant to meet your individual needs every time. Implementing the optimum solution from the fields of workpiece handling, transport and processing is the way to be sure of reliable production and so guarantee your success. For series produced furniture to impress your customers with its perfect cost-toperformance ratio.
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M
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Panel store
BARGSTEDT takes care of warehousing technology and transport logistics including feeding and stacking
Cutting to size
HOLZMA takes care of part optimization, cutting and identification
Lamination
FRIZ and HOMAG take care of lamination (e.g. completeLine)
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① HOLZMA: Cutting to size AKUK
② BARGSTEDT, HOMAG, WEEKE: Sizing and edge processing including drilling operations with automatic feeding/stacking
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③ WEEKE: Extended drilling ④ LIGMATECH: Packaging line
Panel sizing and edge processing
HOMAG Guarantee of successful sizing and edge processing
Drilling and hardware mounting systems
WEEKE Impressive drilling and hardware mounting systems
Assembly and packaging
LIGMATECH Assembly and packaging as well as associated handling
The number of parts per shift sets the pace
Parts per shift – this is a performance statistic you know only too well. This is why the HOMAG Group defines this unit with extreme precision for its machines in terms of performance categories. Here are just a few examples based on three HOMAG lines: up to 4,000 parts, up to 6,000 parts, up to 12,000 parts per shift
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HOMAG: Short machine line Workpiece thickness Workpiece length Workpiece width Shift output Edges per pass
HOMAG: Sizing and edge banding including drilling Workpiece thickness Workpiece length Workpiece width Shift output Edges per pass
12 - 40 mm (optionally 8 - 100 mm) 220 - 2,500 mm (optionally max. 3,000 mm) 240 - 1,200 mm up to 4,000 parts / shift 2
12 - 40 mm (optionally 8 - 100 mm) 220 - 2,500 mm (optionally max. 3,000 mm) 240 - 1,200 mm up to 6,000 parts / shift 4
HOMAG: Sizing and edge banding including drilling and dividing cut 12 - 40 mm (optionally 8 - 100 mm) Workpiece thickness 220 - 2,500 mm (optionally max. 3,000 mm) Workpiece length 240 - 1,200 mm Workpiece width up to 12,000 parts / shift Shift output 6 Edges per pass
BARGSTEDT Feeding
HOMAG Edge banding machine
WEEKE Drilling machine
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① BARGSTEDT: Feeding ② HOMAG: Edge processing ③ BARGSTEDT: Stacking
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① BARGSTEDT: Feeding
③ HOMAG: Turning ④ HOMAG: Edge processing
② HOMAG: Edge processing
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① BARGSTEDT: Feeding
③ HOMAG: Edge processing
② HOMAG: Edge processing
④ WEEKE: Drilling
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⑤ HOMAG: Dividing ⑥ BARGSTEDT: Displacement
⑤ WEEKE: Drilling ⑥ BARGSTEDT: Stacking
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⑦ HOMAG: Edge processing ⑧ BARGSTEDT: Stacking
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Batch size 1 production 23
Flexibility through batch size 1 production
Ever more unique design for that extra touch of exclusivity – this is what every customer is looking for in a personal furnishing solution. In Europe particularly, the trend is now moving increasingly towards batch size one production. For years now, the HOMAG Group has been equipping whole production lines to cope with this demand. Years of experience, widely diverse technical solutions and an impressive array of references: These are the assurance you need before making this kind of investment.
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Storage
BARGSTEDT Panel store
Dividing and cutting to size
HOLZMA and HOMAG Dividing and cutting to size
Buffering/sorting
BARGSTEDT Buffering/sorting
Sizing and edge processing
HOMAG Panel sizing and edge processing
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Order picking and sorting
BARGSTEDT Order picking and sorting
Drilling and hardware systems
WEEKE Drilling and hardware systems
Assembly
LIGMATECH Assembly technology
Packaging
LIGMATECH Packaging
Optimum solutions to address your needs
For batch size one production too, the HOMAG Group defines almost all its machines according to performance classes. The indication “parts per shift� provides you with an initial orientation: up to 300 parts, up to 500 parts, up to 1,000, up to 6,500 parts
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Solution for up to 300 parts per shift Workpiece thickness Workpiece length Workpiece width Shift output
Solution for up to 500 parts per shift Workpiece thickness Workpiece length Workpiece width Shift output
Solution for up to 1,000 parts per shift Workpiece thickness Workpiece length Workpiece width Shift output
19 - 22 mm 220 - 2,500 mm 240 - 1,200 mm up to 300 parts / shift
19 - 22 mm 220 - 2,500 mm 240 - 1,200 mm up to 500 parts / shift
19 - 22 mm 220 - 2,500 mm 240 - 1,200 mm up to 1,000 parts / shift
Edge processing with rotation
Chaotic stacking
Considerable edging magazine
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① ② ① HOLZMA: Saw ② HOMAG: Edge processing with rotation
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① BARGSTEDT: Panel store ② HOLZMA: Saw ③ HOMAG: Edge processing with rotation
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④ WEEKE: Drilling and hardware mounting machine
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① BARGSTEDT: Panel store ② HOMAG: Cutting to size ③ BARGSTEDT: Sorting buffer
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④ HOMAG: Edge processing
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⑤ WEEKE: Drilling and hardware mounting machine ⑥ LIGMATECH: Assembly and packaging line
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Fully networked batch size one plant
What you see here is an example of a fully automated batch size one production plant. It offers an impressive fully automated part flow and a wide range of other technical highlights: a bufferdecoupled cutting station for a further processing operation, fully automatic labelling in the cutting station and drilling in throughfeed. This solution is an example of complete HOMAG Group machine networking in its purest form. A plant of this type is able to process up to 6,500 parts per shift.
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â‘
â‘Ą
Panel store
Saw
Storage system
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③ 0°
90°
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Solution for up to 6,500 parts per shift Workpiece thickness Workpiece length Workpiece width Shift output
19 - 22 mm 220 - 2,500 mm 240 - 1,200 mm up to 6,500 parts / shift
① BARGSTEDT: Area storage system ② HOLZMA: Cutting to size and labelling ③ BARGSTEDT: Buffer system ④ HOMAG: Sizing and edge banding including drilling in throughfeed ⑤ BARGSTEDT: Porcupine storage system
Edging magazine
Edge banding machine for transverse edging
Porcupine storage system
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Production of complex individual parts 33 31
Your challenge: Complex individual parts
The fully automated production of freeform parts poses a particular challenge. This type of part includes curved shapes and sweeping surfaces of the kind found in ship fittings or caravan interiors. Here, HOMAG offers solutions using inter-coordinated machines. These permit economical industrial production in small batch sizes or even batch size 1.
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Dividing and cutting to size
HOMAG and WEEKE Dividing and cutting to size
Panel sizing and edge processing
HOMAG Panel sizing and edge processing
Intermediate and buffer storage
BARGSTEDT Intermediate and buffer storage
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Drilling and hardware systems
WEEKE Drilling and hardware systems
Assembly
LIGMATECH Assembly technology
Packaging
LIGMATECH Packaging
Custom-tailored systems for your specific requirement No matter which machine or system you opt for: When you invest in a solution from the HOMAG Group you are buying into a whole range of benefits for the future. Our versatile complete solutions benefiting from innovative technology provide the assurance of sustainable high productivity. Examples of these are provided by the following performance categories:
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HOMAG leanFactory Processing dimension X Processing dimension Y Machine dimensions Shift output
Processing dimension X Processing dimension Y Machine dimensions Shift output
Processing dimension X Single occupation Processing dimension Y Machine dimensions Shift output
6,000 mm 2,100 mm 14.5 x 5.3 x 3.8 mm up to 300 parts
WEEKE Vantage 38
HOMAG BAZ 222
3,700 mm
4,000 mm
2,100 mm
2,100 mm
6.85 x 5.6 x 2.0 mm
8.75 x 5.3 x 3.0 mm up to 500 parts
HOMAG BOF 612
HOMAG BAZ 723
1,830 mm
3,050 mm
3,700 mm
6,230 mm
1,550 mm
1,880 mm
9.85 x 9.25 x 3.0 mm
13.0 x 7.0 x 3.3 mm up to 850 parts
HOMAG Processing centre for edge banding
HOMAG Drilling unit and 5-axis head
HOMAG Sawing unit
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① HOMAG: leanFactory
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① WEEKE: Vantage 38L ② HOMAG: BAZ 222
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① HOMAG: BOF 612 ② HOMAG: BAZ 723
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Technical highlights laserTec · completeLine · Postforming technique · combiLine · Material handling · Lightweight panels 41
Bild Verfahrenstechnik
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laserTec 43
A new era in edge processing. With the laser joining technique, HOMAG has developed the next technology generation for top-quality narrow edge sealing. Under patent law in Germany only usable with Rehau edge!
High-grade products with a sophisticated design can now be manufactured using the new laserTec technology. This groundbreaking HOMAG patented innovation heralds the start of a new era in edge processing, defining a whole
new quality standard. Heating the edge using a laser produces a mechanical and chemical edge sealing effect with an aesthetically pleasing zero joint.
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completeLine 45
completeLine plants coat the surface of an unfinished panel and simultaneously seal the narrow surface of the longitudinal side. The material being laminated is wrapped with foil or paper in a continuous process. The result: a workpiece which has no visible joint along the longitudinal edge – with an identical appearance of the face and narrow surface.
Benefits of completeLine • High performance through use of the continuous process. • High output with speeds of up to 60 m/min. • Result: Optically top quality product produced using low-cost substrate material • Practically unlimited scope for creativity: Suitable decor papers (from 30 g/m²) are available in a wide range of colours
• Easy to keep abreast of new trends • Thermoplastic foils can be laminated for indoor and outdoor use • Different profile shapes possible along the longitudinal side • The process supports three different glue types • Reduced storage costs for coated material • Extremely good cost-to-performance ratio of the end product
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Postforming process 47
Sizing
Glue application
Activation
Bending
Post-processing
Postforming panels used as worktops form the focal point of the kitchen, and so determine its character. The worktop will be exposed to extremes of stress during the life of the kitchen. This is why particular importance should be attached to the top-quality manufacturing and processing quality of this type of panel.
Postforming – when it really matters The HOMAG postforming technique is the ideal way to produce a topquality appearance in the edge area. In addition to the classical postforming technique permitting bending radii up to a maximum of eight times the laminate thickness, it is now also possible to process a radius of ≤ 3 mm. This allows you to produce a jointless design in the visible section of the furniture: The surface and edge appear to have been created from a single mould with excellent surface quality! Processable materials are HPL, CPL or plastics.
Benefits of postforming • Uniform appearance of the face and narrow surface • No glue joint along the longitudinal edge • Wide range of profile types possible along the longitudinal edge • Easy-to-automate process (continuous production)
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combiLine 55 49
Specifically for high-end batch size 1 production, panel dividing specialist HOLZMA equipped an angular plant with an additional router. This innovative unit is integrated in the rip saw and performs most recutting processes automatically, saving time and money in order-based production.
Output:
Costs:
• Maximum cutting speeds • Cuts single panels or complete books • Proven HOLZMA sawing technology • HOLZMA optimization and simulation expertise
• Minimal piece costs • Low tooling costs • Low energy consumption. For instance lower extraction volume than with pure routing solutions • Improved cost-to-performance ratio over conventional solutions
Flexibility: • Sawing and routing in a single pass • For cutting single panels or complete books • Suitable for dividing thin panels and pressure-sensitive materials
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Material handling 51
Top priority: Greater benefit and profitability for you! Logistic solutions from BARGSTEDT are designed using the modular principle. We put together reliable components from an ingeniously devised modular range to create optimum customer-specific solutions.
An end to material congestion No matter whether storage, buffering or sorting, logistic solutions from BARGSTEDT permit enormous productivity increases and considerable savings to be achieved. Using software solutions, for instance to manage your storage data or take charge of complex sorting tasks, you will reduce waiting time for your components and so benefit from a continuous material flow.
Benefits of automatic handling systems • Optimum throughput time • Shorter waiting time • Maximum space utilization • Higher level of usage • Optimum material flow • Less damage due to manual transport • High degree of material flow transparency
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Lightweight panels 53
The lightweight panel is an innovative solution using wood-based material which couples low intrinsic weight with high strength values. Using a sandwich construction of honeycomb material and conventional panel materials, this product sets whole new standards in furniture design. The HOMAG Group offers solutions for the manufacture of honeycomb panels ranging right through to finishing processes on the end product.
The edge sealing of frameless honeycomb panels calls for innovative new technologies. HOMAG offers a range of options for edge sealing which permit manufacture of the optimum finished product. One of the most economical solutions is the HOMAG patented doubleEdge
technique, in which the decor edge and the support edge are simultaneously glued and the narrow surface sealed. This technology can be used both for throughfeed processing and also in stationary applications.
Lightweight construction expertise
The HOMAG Group offers economical, innovative solutions for lightweight construction technology. From the manufacture of the lightweight panel through narrow surface sealing to drilling and hardware mounting technology, the HOMAG Group has an outstanding command of the entire process chain. Make use of our comprehensive expertise in a market segment with promising market potential.
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Panel production
Sawing
Outset situation
Surface laminating
Panel cutting
Panel coating
Surface laminating Individual lightweight panels with bar (TORWEGGE)
Decorative edge on bar
Gluing in of bar
Frameless large-format lightweight panel (e.g. Egger, Eurolight)
Surface laminating
Panel cutting Thick edging without bar
Thick edging on shaped workpieces
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Panel sizing and edge banding
Edge sealing
Drilling and hardware mounting
Hardware technology
Throughfeed technology, straight workpieces
Conventional hardware mounting
Special screw (H채fele)
doubleEdge without rebate Expanding / glue cartridge dowel AEROFIX 100
Stationary technology, shaped workpieces
doubleEdge without rebate on shaped workpieces
(H채fele/Zimmer Kunststofftechnik)
Assembly/packaging
Assembly
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Software Simulation 路 Identification 路 Manufacturing execution system 57
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Simulation 59
Highly dynamic processes within your production can be very realistically simulated using flexible parameterizable models. Performance can be assessed on the basis of your own individual production spectrum using simulation technology. This service allows you to gain a clear insight into what goes on in your production.
Benefits of simulation
Objectives of simulation technology
• Reliable statements about productivity and throughfeed times • Analysis and optimization of bottlenecks • Cost-to-benefit ratio appr. 1:6 (VDI Guideline 3633) • Sensitivity analysis • Review of fault scenarios and minimization of consequences • Interactive system optimization • Avoidance of costly overdimensioning • Minimization of entrepreneurial risk • Effective support for presentation and team discussion of projects • Reduction of commissioning times
• Minimization of throughfeed times • Maximization of plant performance • Reduction of the ramp-up phase in new installations • Generation of objective assessment criteria for production • Utilization in the planning and operating phase
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Identification 61
To maximize function, an efficient material flow requires organizational framework conditions. Use of a barcode allows workpiece identification.
Benefits of identification • Clear assignment of workpiece and information • Individual information can be depicted on the barcode • Customer-specific barcode design
• No manual input at the machine required • Automatic exchange of information between production and production engineering • Alternatively, an RFID (chip with radio frequency technology) can be used
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Production control using the MOS manufacturing execution system 63
The efficiency and performance of your production is dependent on the organization. The MOS manufacturing execution system helps you prepare specific, targeted data from your production engineering department for manufacturing.
The manufacturing execution system accepts production orders from the ERP system and offers a wide range of practical functions which can run either interactively or automatically:
• Completeness check, e.g. in assembly or shipping
• Optimization of the job sequence (for instance sorting according to materials) • Supplementation of technical master data (master data manager) • Grouping of production batches • Dispatch of production orders to machines and workstations • Printing of production documents in production engineering • Data output to machines in machine-specific data formats • Data output at manual workstations • Identification of workpieces, stacks, containers etc. during production • Order tracking with feedback to the ERP system
• Precision planning of customer and production orders • Extension of cutting optimization taking into account must and can dividing processes • Generation and evaluation of postproduction orders • Edge preview for edge processing machines
Other benefits:
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lifeline l service Servicing 路 Financing 65
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Servicing 67
Proximity and accessibility are fundamental to perfect servicing. The HOMAG Group offers you both – the world over. We offer individually designed servicing contracts specifically for our plant customers.
Hotline & teleservice
Parts & accessories
On-site servicing
• Hotline: Your direct link to your servicing partner • Really connected: Teleservice by modem and/or TeleServiceNet reduces the need for actual callouts by around half • Expert and immediate advice on all aspects of mechanical, control, electrical and process engineering • Information in multiple languages • Maximum service at minimum costs
• Immediate availability of spares • Minimized standstill times • Possibility of prophylactic exchange of wearing parts by on-site servicing • Decentral warehousing permits greater flexibility without compromising availability
• Installation: Configured for performance right from day one • Inspections: Demand-based and comprehensive • Made-to-measure maintenance and repair service • Production support and optimization by experts
Training • Optimum plant application • The fast way to continuously high productivity
We will be pleased to inform you about our extensive range of further services
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Financing 69
Anyone looking for an affordable way to ensure maximum flexibility needs to find an optimum balance between liquidity and necessary investment. HOMAG Finance helps you in this endeavour, for instance with export and project financing. Working in cooperation with international banking partners, we use a world-wide network of credit insurances to help you implement your investment project quickly.
HOMAG Finance works with a small and efficient team which is closely linked to international partners, enabling it to ensure the fast implementation of export financing arrangements worldwide. As our customer, you liaise with just one contact partner who takes care of all the arrangements – saving you time and cutting down on admin costs.
The benefits at a glance • Leaves your equity untouched • Greater financial leeway • Individually tailored financing offers • Made-to-measure contract solutions in respect of repayment term and conditions • Fast implementation due to small, efficient team and short distances • Complete flexibility: Leasing, financing, hire purchase or other types of financing
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Convincing arguments Resource efficiency 路 Quality assurance 路 References 71
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Resource efficiency 73
With energy and raw material costs at a relatively high level and set to rise further in the medium term, resourcesaving production is vital for any company aiming to stay abreast of its competitors. This need has prompted HOMAG Group to develop a number of pioneering solutions in close cooperation with customers and suppliers. The focus is on increasing machine and plant productivity with a view to cutting down on use of resources and energy consumption. Fast set-up times, special-purpose tools with internal suc-
tion, the latest control technology and optimum servicing are all ways in which machines and plants can be made to work more efficiently. Power consumption has been significantly reduced in machines by the addition of features such as standby circuits and modern extraction concepts. Modern machine engineering concepts from the HOMAG Group – permitting for instance the manufacture and processing of lightweight panels or modern software solutions such as Cut Rite - help save money due to the lower consumption of raw materials.
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© EGGER
Quality assurance 75
Quality and quality assurance are a focal issue throughout the entire HOMAG Group. Certification to DIN EN ISO 9001 and also the environmental standard DIN ISO 14001 testify to our commitment to quality. Adherence to international safety requirements are just as much part of our corporate standard as close, continuous cooperation with the German Employers’ Liability Insurance Association. We take the safety of your personnel very seriously. This is why we work continuously to develop technical innovations to improve occupational safety
and ergonomy. Questions such as noise and dust reduction are just as decisive as on-going improvements in the field of operator prompting using intuitively understandable software solutions. Our conception of “quality” naturally also includes the quality, durability and reliability of our products. And finally, for us the all-important deciding quality factors are the perfection of your finished furniture products and your satisfaction.
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References 77
Christian Schaaf Managing Director of the furniture factory Perters GmbH as subsidiary of the group of companies Pelipal
Håkan Eriksson, Deputy Sector Manager, Swedwood
“We were looking to invest in a new, flexible plant with a partner able to supply us with fully networked systems and with experience right across the warehousing technology, cutting, handling and edging processes.
“Our high quality standards and high capacity utilization in production mean we cannot afford to make mistakes in the configuration of our systems.
The solution supplied by the HOMAG Group fully met our expectations in all these areas. The principle of ‘everything from a single source’, from the control system to the machine technology, was what convinced us. HOMAG Engineering proved a reliable partner throughout every phase of the project, from the plant concept through to project processing.”
Swedwood stands for long-term sustainability coupled with a high quality standard and efficient production. This is just one of the reasons why we appreciate our partnership with the HOMAG Group.”