Software Solution Efficient Machining Relieves Employees

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At Schubert Fertigungstechnik, hardly any machine is equipped without a robot. To achieve this level of automation while maintaining transparent oversight of production quality, they rely on Blum-Novotest.

Theo Drechsel is a freelance author

Schubert Fertigungstechnik originated as a production facility for the Waiblingen-based packaging manufacturer Höfliger & Karg in Bartholomä in the Ostalb region. In the early 1970s, the company was sold to Bosch. As part of the centralization of Bosch locations, the companies Schubert and Edelmann joined in, and in the early 2000s, Schubert took over the shares. The packaging machine manufacturer Gerhard Schubert GmbH from Crailsheim still accounts for about 70 percent of the orders for today’s Schubert Fertigungstechnik.

In Bartholomä, 85 highly skilled employees are employed, most of whom come from the nearby area. The company's machinery primarily includes CNC-controlled milling and turning centers as well as combined turning/milling machines. Additionally, there are some grinding machines, 3D printers for plastic and metal, and an assembly line for components.

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Schubert Fertigungstechnik GmbH has defined specific machine types for various component sizes. This means that several identical machining centers are always placed side by side in the halls to produce parts in the size classes S, M, L, and XL.

This has the great advantage that we can flexibly distribute orders across the machines. If one machine is defective, the order can be completed on the neighboring machine. Naturally, this also simplifies maintenance and spare parts management, as well as employee training.

Jens Grieser, Geschäftsführer, Schubert Fertigungstechnik

In the XL size range, Schubert relies on horizontal centers from DMG Mori, while in the S and M range, Fanuc Robodrill machining centers with automation solutions from Häberle Feinmechanik are used. Notable during a visit to the halls is the high number of robots and automation solutions at the machines. Schubert is not a series manufacturer; typical batch sizes range from three to ten pieces, sometimes up to fewer than 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 imposing a night shift on the employees. Ideally, we aim to make early and late shifts as unnecessary as possible as well. However, the quality must be right at all times!

Jens Grieser, Geschäftsführer, Schubert Fertigungstechnik

With this in mind, Erhard Strobel, sales technician at Blum-Novotest, found a receptive audience with Markus Maier, who looks after the Robodrill-Plus-Big-K systems at Schubert, with the Blum software Form Control X:

For us, Form Control X was very interesting. After all, we produce four variants of a part on one machine, each with about 60 pieces per variant and a runtime of between 10 and 40 minutes per piece – we can only achieve this if the machines run continuously. And it is very important to monitor quality during unmanned shifts.

Markus Maier, Anlagenbetreuer, Schubert Fertigungstechnik

Form Control X is a client-server-based software solution for the automated measurement and evaluation of machining processes. Blum completely redeveloped the software based on the proven Form Control software, placing a particular focus on the automation of measurement processes. A major advantage of the client-server architecture is that multiple workstations or machines can access the data in the Form Control X database. This allows Maier to conveniently create complex measurement programs at his office workstation or review the measurement values from the previous night.

On a laptop near the machine, the operator monitors the tolerance fluctuations of all measurement values. The display is generally done very simply in the conventional web browser of a PC, laptop, or tablet. "This allows us to ensure that all measurement values are adhered to," Maier emphasizes.

Process-accompanying measurements have the advantage of detecting when a measurement value starts to drift. Long before it falls out of the tolerance range, measures can be taken. This is even more true for broken cutting edges.

Markus Maier, Anlagenbetreuer, Schubert Fertigungstechnik

On the Fanuc centers, components for tool changers in Schubert packaging machines are primarily manufactured. These tools hold, for example, boxes into which a robot then places chocolates. If a different package size or shape is needed, the tool can be changed, and the packaging line is automatically reconfigured.

In these tool changers, multiple pneumatically operated pistons with H7 fittings work in parallel. The bores in which the pistons operate must be manufactured with precise parallelism and the correct diameter. It is essential to measure every produced part to ensure reliable operation later. A stoppage in a packaging machine can be extremely costly, for example, in the mentioned chocolate production – if the packaging line comes to a halt, the sweet's production must also be stopped, as the liquid chocolate and other ingredients solidify and spoil.

In our case, pre-assembly is timed, which means we have to deliver on very short notice. A problem with the machine doesn’t just affect us but also the processes at the parent company.

Jens Grieser, Geschäftsführer, Schubert Fertigungstechnik

Therefore, during the beta test prior to purchasing Form Control X, the accuracy of the measurements in the machine was continuously verified; the deviations were in the range of a few thousandths of a millimeter.

The designers of the packaging machines define dimensions that are critical to functionality and should be inspected during production. In Bartholomä, the NC programs are then created, and the measurement subprograms are inserted at the appropriate points.

"We work together here: We, the employees at the machine, are responsible for quality and therefore decide together with the NC programmers which dimensions are recorded with the Blum measurement cycles and stored in Form Control X," emphasizes Markus Maier. "This way, we also have the knowledge to understand the measurements and make improvements."

During the introduction phase of Form Control X, the contact with the Blum specialists was very close: “It was clear that the new software was a passion project. The programmers were extremely committed to us during the beta test and were always available when we had questions,” recalls Maier. “The training was also excellent; we were able to implement the software operation quickly. Nowadays, we only have to program a new part every two or three weeks, but we still manage well with the software because it is very intuitive.”

Form Control X also allows the employees in Bartholomä to focus more on their actual work:

In the past, I first had to check the components produced overnight to ensure they were within tolerance – this took quite some time. Today, a glance at the screen is enough – I can immediately see in the graphical representation of the Form Control X web client whether the tolerances have been met. I can then either react immediately or continue production straight away.

Markus Maier, Anlagenbetreuer, Schubert Fertigungstechnik

Meanwhile, all dimensions with tolerances under a tenth of a millimeter are measured automatically, as well as form and position tolerances. These are important because many parts are machined in two setups, making the position of the second machining dependent on the surfaces created during the first setup. This is another reason why Form Control brings significant improvements to daily work: “First of all, I no longer have to work shifts and can complete my tasks during regular working hours – that’s a big win for me! Additionally, working at the machine is more relaxed because the process is transparent, and we always know where we stand in terms of quality – that’s very reassuring,” says Maier, highly satisfied. “And finally, Form Control X frees me from measuring tasks because they are automated. This allows me to focus more on my actual work.”

For every production batch, the first and last measurement reports are printed and archived; apart from that, all measurements are available in the Form Control database. This is particularly useful for checking the service life of tools. “And for me, it’s also reassuring to always be able to track where we stand in terms of quality. That’s why Form Control X is an essential component for the automation of machining processes and plays a crucial role for us, as we aim for a very high level of automation,” concludes Jens Grieser positively. “Of course, the machines and the parts spectrum must be suitable to maximize the software’s benefits – and that’s the case for us. Based on the good experiences with the Fanuc centers, we are determined to use Form Control X on many additional machines to further boost our productivity.” This approach at Schubert Fertigungstechnik will surely allow even more workers to transition out of shift work.

*Theo Drechsel is a freelance author.