Flexibility and Efficiency in Small Batch Production through Automation

At Dorfmüller, fasteners are considered a core competency, producing nuts, bolts, washers, and custom parts in large dimensions for all relevant industries, including shipbuilding, wind power, railways, gear manufacturing, and the energy sector. Specifically, this means nuts up to size M200, corresponding washers, special screws up to 2 meters long, and custom parts up to 800mm in diameter made from various steels and in different shapes. The company's history dates back to 1884, and today it employs 60 people.

The fifth generation, Lucas Dorfmüller, is now in management. "Knowing today what will be needed tomorrow" is the motto on their website, with a note clarifying that while they don't possess clairvoyant abilities, they aim to be as well-prepared as possible. This proactive approach ensures that customer needs are anticipated and met efficiently. In addition to a large raw material warehouse and a modern machine park, this also includes the automation of machining processes. Specifically, this means the automatic loading and unloading of machines with automation solutions that are both flexible and offer a high degree of autonomy. Such automation ensures consistent quality and reliability, which are crucial for customer satisfaction. Dorfmüller decided to venture into robotic automation in 2017.

During an online search for potential system providers, they came across EGS Automation, a brand of AMETEK from Donaueschingen, Germany. EGS has been developing and implementing automation solutions for machine tools since 1996 and has been offering standardized robot solutions under the product name SUMO since 1999.

Initially, Dorfmüller wanted to automate an existing lathe or milling machine. EGS developed concepts and made initial offers. However, it was then decided to automate a machining center that was due for new acquisition. The workpieces to be machined should be loaded and unloaded.

This decision was driven by the need to enhance production efficiency and meet customer demands more effectively. Considering all requirements, the choice fell on the SUMO Flexiplex from EGS. This solution can be retooled for different part sizes in just a few minutes without tools. The workpieces can have different geometries and are stored on a multi-lane conveyor system and fed to arobot. The robot loads and unloads the machine. No workpiece carriers are required. The automation was installed on a Brother Speedio machining center. The machine offers a side loading door, so the front door remains fully accessible, e.g., for setup tasks on the machine or for manual loading of small and special series. "Regarding interface coordination, we initially feared that difficulties might arise and responsibilities might be shifted between the machine supplier and the automator. However, this concern was completely unfounded. EGS clarified everything directly with the machine supplier, and it worked plug and play," recalls Lucas Dorfmüller about the commissioning. This seamless integration ensures minimal downtime and uninterrupted service for customers.