Dual-Spindle Machining Digitization as the Key to Series Production Maturity

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Two powerful machining centers and digital solutions from Grob ensure reliable and optimized series production at the Böllinger Group. Downtimes and process deviations can now be detected and resolved early.

The Böllinger Group, headquartered in Bad Friedrichshall (Germany), is a specialist in high-precision prototyping and small-series production. The company is sought after where the highest demands on quality, precision, and flexibility are required. In 2023, the Böllinger Group faced a pivotal decision: a challenging customer project required the implementation of industrial series production for the first time. This transformation demanded not only new machinery but also a fully thought-out production and digitalization concept.

We wanted to expand our portfolio while demonstrating that we can meet the highest standards in series production.

Thomas Gilliar, Managing Director at Böllinger Group

"For that, we needed not only the right technology but also a partner who could support the entire project from a single source—technologically, organizationally, and digitally."

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After an intensive market analysis, the decision was made in favor of Grob—not only because of its wide machine portfolio but also due to its ability to deliver complete process chains, including digital solutions, from a single source.

Project Start With Speed

Just a few days after the initial meeting, the Grob team presented concrete solution concepts. "We were impressed by how quickly Grob not only understood our requirements but also translated them into an actionable concept," says Thomas Gilliar to this day. The project implementation was equally efficient: planning, delivery, installation, and commissioning were completed on schedule—a crucial factor in realizing the customer project.

The core of the new production line at the Böllinger Group consists of two highly dynamic, twin-spindle machining centers of the G320 type. These were integrated into a third-party automation system that includes automated workpiece feeding, high-pressure cleaning, vacuum drying, and a visual inspection station. This made it possible to successfully transition into series production, both technologically and process-wise.

A central element of the project was the consistent digitalization of processes. From the outset, it was clear that stable and efficient series production could only be achieved through digital transparency. With the products from Grob-NET4Industry, the Böllinger Group was able not only to monitor the entire production process but also to guarantee the traceability of the manufactured parts—an increasingly important topic for the company and its customers.

Grob4PartFlow provides us with a complete history of every manufactured component at the push of a button. "In case of inquiries or quality evaluations, we can trace at any time when and which part went through which station."

Peter Feucht, Production Manager at Böllinger Group

Digitalization also brings clear advantages for maintenance and shopfloor management: With Grob4Line, machine status, alarms, and analyses are always available on mobile devices—whether on a tablet in production or in the office. "Our response times have significantly improved," says Sebastian Hübner, Team Leader Series Production at the Böllinger Group. "This allows us to detect issues earlier and reduce downtime."

Analyze Machine Data in Real Time

Another key component of the new series production is Grob4Analyze—a powerful analysis tool that evaluates machine data in real time, enabling continuous optimization of the production process. Downtimes, process deviations, and quality trends can be identified and addressed early on. This not only provides the Böllinger Group with transparency over ongoing production but also establishes a solid foundation for making data-driven decisions.

"With Grob4Analyze, we provide our customers with a tool that not only increases efficiency but also enables comprehensive process data monitoring and sustainable quality improvement," explains Benedikt Gundling, Product Manager Digital Products at Grob. "Especially in series production, this information is crucial for consistently manufacturing at a high level."

Tool Management on a New Level

Especially in the prototype sector, where frequent tool changes are necessary, Grob4TDX has also proven to be an enormous efficiency driver for the Böllinger Group. "The digital management and automatic synchronization of tool data save us a lot of time and prevent errors," says Stefan Kniel, Production Planning at the Böllinger Group.

Tool data can easily be transferred, synchronized, and documented via scan – significantly increasing process reliability.

Stefan Kniel, Preparation Work at Böllinger Group

The project with the Böllinger Group was also special for Grob: "We didn't just deliver machines here; we ushered in a new era together with the customer," emphasizes Benedikt Gundling. "It was important to us to appear as a partner on equal footing from the very beginning—with great technical depth as well as a lot of flexibility and commitment."

Especially for medium-sized companies aiming to move towards Industry 4.0, solutions are needed that not only work technically but also provide real added value in everyday life. That is exactly what we have achieved together here.

Benedikt Gundling, Production Manager Digital Products at Grob

The result of the collaboration with Grob: a highly efficient production line that meets the demanding cycle times and quality requirements of the Böllinger Group—and even exceeds expectations. "The new production line has tremendous appeal," says Thomas Gilliar. "We regularly receive new project inquiries and are already working on developing further concepts with Grob."

What the Böllinger Group takes away from the project is clear: Digitization is an added value and boosts performance. "Our employees see that digital tools help them—with planning, evaluation, and daily work," emphasizes Thomas Gilliar. "This promotes acceptance and the willingness to embrace new technologies."

His advice to other companies: "You don't have to make digitization complicated—but you do have to take it seriously. Only those who understand processes can digitize them. And with Grob, we had a partner who accompanied us on this journey not only technically but also on a personal level."

*Anna-Lena Rehder, Group Marketing Lead, Grob-Werke GmbH & Co. KG

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