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The task was demanding – to create a production system that could manufacture a wide variety of parts equally economically and flexibly. "In our production facility, we faced the challenge of producing flexibly – whether prototypes, series, small series, individual parts, or particularly large and heavy parts," says Mevlüt Isik, machine operator in Hall 7, describing the initial situation. The vision was clear: a production facility that could master this balancing act with ease while also reducing production costs in the long term.

In-house technology for in-house production

Instead of relying on external standard solutions, GROB-WERKE decided to take a consistently independent approach – with technology from its own in-house development. The goal was to further automate production and develop a solution that precisely met internal requirements. The combination of pallet and robot automation was deliberately chosen in order to combine high autonomy times with maximum flexibility without restricting processes through rigid standards.

The solution: Tailor-made automation from three core systems

The result is a flexible automation solution that combines several GROB products: The PSS-L450 linear pallet storage system handles pallet handling, the GRC-R150 robot cell takes care of parts handling, and three G150 universal machines have been integrated with special clamping fixtures as part of a master machine concept. Complex clamping fixtures are clamped manually via the PSS-L450, while smaller and larger cubic components are handled automatically by the robot cell. An additional screwdriving and stamping station within the robot cell automates further work steps and ensures even greater efficiency.

Clear workpiece flow and maximum transparency

The workpiece flow follows a clear principle: large parts run through the PSS-L450, while smaller parts are handled fully automatically by the GRC-R150. With unmanned production times of up to 350 hours per week, as in Hall 7 at GROB, process stability, tool life, and continuous monitoring are particularly crucial. This is exactly where the in-house control software GROB⁴Automation plays to its strengths: it organizes production orders visually, displays processes in chronological order, and thus ensures maximum transparency.

The system is supervised by five employees working in flexible shift patterns – two machine operators and one setter are responsible for monitoring, setup, and quality control. This ensures an optimal balance between human and machine interaction. In addition to its high flexibility, the system scores particularly well with its enormous autonomy time: up to 46 pallets and around 1,000 parts can be stored in the system. This reduces personnel costs, increases machine utilization, and provides valuable unmanned production hours, especially on weekends.

Perfect interaction for in-house production

"This system is an important step toward an automated future," summarizes Ralph Birkle, project team leader at GROB-WERKE. "It shows that we not only develop innovative products for our customers, but also use them successfully in our own production."

With the automation in Hall 7, GROB-WERKE is proving that its products set standards not only in the customer environment, but also in its own factory. The project is a prime example of the combination of engineering expertise and practical manufacturing experience – and a clear signal of where the journey is headed in terms of flexibility, efficiency, and autonomy.