High-efficiency machining is the program at Schubert Fertigungstechnik in Bartholomä: Hardly any machine is without a robot that handles loading and unloading, enabling long, unmanned ghost shifts. To achieve this automation while keeping manufacturing quality transparent, Schubert uses the FormControl X software from Blum-Novotest.
During a visit to the halls of Schubert Fertigungstechnik GmbH, the high number of robots and automation solutions at the machines immediately stands out. The company is not a series manufacturer; typical batch sizes range from three to ten pieces, sometimes up to under 100 pieces. 'We have been working for a long time to achieve 18 to 22 hours of autonomous machine time. This allows us to run the machines around the clock without having to impose a night shift on the employees,' explains Jens Grieser, the managing director responsible for the technical area. 'Ideally, it would also be possible to make early and late shifts as redundant as possible. However, quality must always be right!'
With this in mind, Erhard Strobel, sales technician at Blum-Novotest, found open ears in Bartholomä with FormControl X, as the BLUM software – a client-server-based solution for automated measurement and evaluation of machining processes – was very interesting for Schubert. After all, four variants of a part are manufactured on one machine, each with about 60 parts per variant and a runtime of between 10 and 40 minutes per part – but only if the machines run completely.
It is very important to keep an eye on quality even during unmanned shifts. Thanks to FormControl X, specialists can be sure that all measurement values are maintained. Process-accompanying measurement has the advantage that one can see when a measurement value begins to drift. Long before it is out of tolerance, measures can be taken. This is even more true for broken tool edges.
The flexible possibilities of how FormControl X can influence the machine are very interesting: In one case, the manufacturing process is only stopped when the same deviation has been measured on two parts in succession – this excludes the possibility that a chip adhered to the measurement point during the first measurement. 'It is also possible to measure every fifth part, for example. In the case of an outlier, measuring does not wait for another five parts, but is immediately measured again during the next processing to exclude a chip at the measurement point,' emphasizes Erhard Strobel.
'Only then does the program decide based on the specification whether the next part is processed, the machine interrupts processing, or switches to the production of another part where different tools are used.'
On the Fanuc Robodrill machining centers, components for tool changers of the Schubert packaging machines are primarily manufactured. These tools hold boxes into which a robot then places chocolates. If a different packaging size or shape is needed, the tool can be changed, and the packaging line can be automatically retooled. In these tool changers, several parallel pneumatic cylinders work with H7 fit. The holes in which the cylinders operate must be manufactured very precisely parallel and in the appropriate diameter.
Here, it is necessary to measure every produced part to ensure reliable operation later. A stop in a packaging machine can become extremely expensive, for example, in the mentioned chocolate production: If the packaging line stops, the production of the sweetness must also be shut down, and the liquid chocolate and other ingredients solidify and spoil. Additionally, at Schubert, the pre-assembly is timed, which means that very short delivery times are required.
A problem on the machine also affects the workflows at the parent company, which accounts for about 70 percent of the orders. Therefore, during the beta test before acquiring FormControl X, the accuracy of the measurement in the machine was continuously checked – the deviations were in the range of a few thousandths of a millimeter.
The designers of the packaging machines define dimensions that are crucial for functionality and are to be checked in production. In Bartholomä, the NC programs are then created, and the measurement subprograms are inserted at the appropriate places. 'We work together here: We employees at the machine are responsible for quality and therefore decide together with the NC programmers which dimensions are to be recorded with the BLUM measurement cycles and stored in FormControl X,' explains Markus Maier, who oversees the RobodrillPlus-Big-K systems. 'This way, we also have the knowledge to trace the measurements and implement improvements.'
During the introduction phase of FormControl X, the contact with the BLUM specialists was very close: In addition to the dedicated support during the beta test by the programmers, Schubert was also convinced by the excellent training. Meanwhile, in Bartholomä, only a new part needs to be programmed every two or three weeks, but the employees still handle the software well because it is very intuitive. It also helps FormControl X to focus more on their actual work. While in the past, some time had to be invested in checking the dimensional accuracy of the parts produced overnight, today a glance at the screen suffices: The graphical representation of the FormControl X web client indicates whether the tolerances have been maintained. Then immediate action can be taken or production can continue directly.
Meanwhile, all measurements with tolerances under one-tenth of a millimeter are measured automatically, as well as form and position tolerances. These are important because many parts are processed in two setups, and therefore the position of the second processing depends on the surfaces produced in the first setup. For this reason, FormControl X brings significant improvements in everyday work:
"The software relieves me of measurement tasks because they are automated. This allows me to focus more on my actual work," reports Markus Maier. "Working on the machine is also more relaxed because the process is transparent, and we always know where we stand in terms of quality – this is very reassuring. Furthermore, I no longer have to work shifts, but can complete my tasks during normal working hours – this is a great benefit for me!"
The number of employees at Schubert Fertigungstechnik who are still 'relieved' from shift work could soon increase: Because after the good experiences at the Fanuc centers, there are plans to use FormControl X on many more machines with the aim of increasing productivity. After all, the BLUM software represents an important building block for the automation of machining processes and plays a crucial role in achieving a very high degree of automation in Bartholomä.
FormControl X has proven itself absolutely at Schubert Fertigungstechnik and has become established: "For every production batch, the first and last measurement protocol are printed and filed, apart from that, all measurements are available in the FormControl database. This is quite interesting for checking tool downtimes," summarizes Jens Grieser. "And it is also reassuring for me to be able to trace at any time where we stand in terms of quality. Of course, the machines and the range of parts must fit to derive the highest benefit from the software – and that is the case with us."
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