“Our focus was on reducing expensive setup times. We needed to significantly extend our machine-side tool stor- age capability,” said Philipp Schneider, head of department at this branch of the group. Thus, the tool storage was upgraded from 80 to a total of 320 spaces and the modular, flexible-configuration rack columns were designed to enable even customer-specific requests to be promptly met. The equipment featured an all-purpose design to pro- vide as much flexibility as possible. During the period when the RLS was integrated into the existing solution, Liebherr worked closely with machining center builder Heckert. Together the two companies sorted out the interface issues between both systems.


Another important point is that operators like working on the RLS. The integrated setup space is located right next to the operator’s side of the machine. The system’s special de- sign enables users to access the automation unit easily. The surrounding window panels in combination with the well-laid- out user interface provide an overview of what’s happening in and around the RLS. Through the intuitive-to-use cell controller software and the graphic user interface, the required functions can be conveniently activated via “drag and drop.” The software, like the entire system, features a modular design. A range of different add-on packages can be hitched onto the basic package to enhance functionality so Liebherr can adapt new applications to deliver process reliability without having to modify the existing computer system. The switch to the RLS for small-batch production is pay- ing dividends for Berger, particularly in terms of efficiency, customer focus, and delivery capability. Given its newly acquired flexibility, the company is able to react immediately even to really short-notice changes in demand. Customers are supplied on time with exactly the models in the quantities they require and are therefore capable of reacting faster in changing market situations. The RLS has also reduced the manufacturing cost impact of setup times significantly and enables more productive use of machining center time cutting parts. The RLS allows operators to set up jobs in parallel with machining time. So the machine tool is not waiting on the next job, thus ensuring that setup costs are not absorbed in machine hour rates. This RLS concept optimizes spindle utilization and maxi- mizes production output. Even an unmanned third shift would


be feasible. Another effect of this changed production philoso- Continued on P116


July 2016 | AdvancedManufacturing.org 49


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