By using robots, MERZ has increased productivity, quality and flexibility, minimized downtimes and shortened delivery times

In the MERZ production facility, the KUKA KR FORTEC F (Foundry) links four machining centers, fills and empties changeover stations and ensures optimal utilization of the machine tools.

KUKA heavy-duty robot enables fully-automatic operation

The KUKA KR FORTEC F (Foundry) moves on a KUKA linear unit of type KL 1500-3 with a length of 18 meters to tend the four production systems installed adjacent to one another. The task of the robot is to load and unload the changeover stations at which the machine pallets with the corresponding workpieces and raw materials are supplied. Serving as the link between the machining centers, it performs the automatic transfer of machine pallets and raw material pallets between the changeover stations, storage areas and machine tools. This enables the four machining centers to work fully automatically around the clock. The automated system has also been integrated into the company’s internal information flows. This ensures automatic provision of the NC and tool data for the machines – a key factor in avoiding unnecessary downtimes and achieving maximum productivity. The application at MERZ was implemented by KUKA system partner wbt automation and production control specialist SOFLEX.
Ideal combination: the KR FORTEC series and the KL 1500-3 linear unit

The KUKA KR 500 R2830 F from the KR FORTEC heavy-duty series covers an exceptionally large working envelope with very long reference load center distances. The compact design of the KR FORTEC series without disruptive contours, together with their more streamlined appearance, makes the robots suitable for use in cramped cells as well as in completely new cell concepts. In the special Foundry variant, the robot is suitable for installations with a high degree of fouling and high temperatures. All robots of the KR FORTEC series are optimized for use on linear units. The KL 1500-3 linear unit has been specially designed by KUKA for high payloads. The combination of robot and linear unit ensured that all the pre-formulated objectives were achieved: shorter delivery times, improved deadline compliance, better machine utilization, increased quality and improved internal procedures.

Since its beginning in 1897, the Godrej Locking Solutions and Systems, a unit of Godrej & Boyce Manufacturing Company Ltd, has set several benchmarks in the locks industry – from the first spring-less lock in 1907 to the iconic ‘NavTal’ in 1954 to the Ultra range in 1995 to the revolutionary 3KS in 2007. From a state-of-the-art manufacturing facility in a suburb of Mumbai, the company provides locking solutions that reach homes, offices, industries and the hearts of millions of people in India and around the world for whom ‘locks’ means Godrej.

A symbol of trust and security for 118 years, lock on almost every Indian home’s front door is of Godrej. It goes to show how the customers have placed their trust and confidence in the company. Since the first lock was manufactured in 1897, it has been Godrej’s endeavor to constantly evolve and design products and services that exceed the expectations of individual and institutional customers. Over the years, the locks have changed in form, function and scope of application, but one thing remains constant – the solid stamp of trust and reliability. The company adheres to global quality norms and hold ISO 9001, ISO 14001 and OHSAS 18001 certifications.

“Initially, we were carrying out manufacturing process on conventional lathe and special purpose machines (SPMs). Since our style of manufacturing is quite flexible, we designed some special fixtures also that matched our machining process. However, later we shifted to vertical machining centres (VMCs) and turning centres as they give us opportunity to machine various designs of locks on a single machine,” the Associate General Manager (Manufacturing) of the company, Mr. MHM Shaikh said.

“We serve all types of customers and customize locks as per demands of the consumer. This is the reason why one can see Godrej lock on almost every Indian door. This trust of customers on us has transformed us into a company that provides locking solutions,” Mr. Shaikh said. Explaining the manufacturing process, the official said they carry out forming, die casting, plating and then machining (that includes milling, drilling, turning, boring etc.) of the products. “In fact we do all the processes that a VMC has been designed to do,” he added.

As on today, the company has over 50 machines of which 20 are Haas machines. “We carry out machining on VMCs, turning centres and turnmill centres. We purchased first Haas machine in 2006 and by 2010 we had 6 Haas machines. After that, we are adding one machine in our kitty almost every year,” the Senior Manager (Manufacturing) of the company, Mr. D N Kharat said.

The methodology adopted by Godrej for selecting any machine tool is that they first prepare an exhaustive list of parameters and features as per the end application. After preliminary round of discussions with various vendors, a comparative analysis is done and 5-7 vendors are selected who match at least 80% of their requirement.

Explaining the rationale behind selecting Haas machines, the officials said that when the company decided to go for CNC machines, it categorized the supplier on the basis of power required to run the machine, operational safety, environment friendliness, end application and above all whether it gives the best productivity in terms of optimized cycle time. “We found everything in Haas and decided to go with them. Besides this, we were satisfied with the maintenance aspect of Haas machines as it involves minimum wear and tear that reduces operational cost. Also, the service support from Haas is excellent and their engineers respond to your call within no time. This adds value to our trust on Haas and its machines,” the officials said.

“The installation of ST10Y turnmill centre from Haas did magic for us. It reduced the cycle time beyond our expectations as it gives us advantage of two machines in one. We plan to add many more from this series,” Mr Shaikh quipped.

“Ever since we installed first Haas machine, the company has helped us a lot in the process that included service and application support. We were able to lessen the machine downtime and increase our productivity. Our end component accuracies are in the range of 20 microns and we are able to meet the same with Haas machines,” Mr Shaikh said and added that Haas machines are true value for money.

“And with continual improvement in terms of precision deliverables and responsiveness to their customers, Haas is worth recommending to the industry. I am sure that with Haas’ support, Godrej Locking Solutions will continue to reap rich dividends in the years to come. It’s a partnership built on trust, support and continual engagement which will certainly go very far,” Mr Shaikh concluded.

Mandelli Sistemi has an experience of over 80 years in the world of machine tools. During these years it has reached the top of the market not only nationally but also at an international level by designing and building machines used in different application sectors. However, it has consolidated its position in two main sectors in particular: energy and aeronautics.

The aeronautic industry is a strategic sector for Mandelli as the main aircraft manufacturers estimate that the world fleet will double in size in the next 20 years from the current 20910 to 42180 with 36700 new airplanes and a $ 5.2 trillion turnover. The main factors for this result are the expected economic growth, especially in the BRICS countries, that will attract businessmen from all over the world, increment in tourism and reduction in the ticket prices.

Mandelli is ready for the challenge with its range of machining centers suitable for working hard material with a complex shape, often requiring turning and milling operations. The raw parts are usually plates which have to be “machined from solid” or they can be forged parts or castings with a considerable amount of allowance to guarantee the absence of defects in the material: the machine tools must, therefore, be very stable for heavy stock removal during the roughing operations, but at the same time, they must also be dynamic and accurate in the finishing operations of complex profiles. Mandelli’s response to this was the Multitasking Machining Center, able to automatically switch from operations with rotating tools to the standard machining operations of a vertical lathe. Mandelli laid its roots on multitasking machining many years ago: way back in 1992 it build the M8 U/T Machining Center, then it passed on to the Storm 1400 with the introduction of the tilting head, followed by the new Spark Line that includes turning/milling machine models for which Mandelli took heed of its past experiences and focused on the fixed table solution. This type of configuration produces excellent performances in terms of stock removal volume and machining precision. The large size rolling guides and the FEM optimised structure are the perfect match between dynamic features and machining rigidity. The Spark Line includes two turning models, respectively able to hold components with Ø1600 and Ø2000 swings and have a loading capacity of up to 7000 kg. The Spark A/T has recently been equipped with various accessories which can be loaded automatically and which further improve the machining flexibility: an extension for turning operations up to a depth of over 600 mm, an angular head for the drilling of internal diameters, motorisation for the facing tools. All these options are available with automatic tool change on the actual accessory.

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