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From prototype plant to industry 4.0 pioneering solution - how Liebherr revolutionized production with SOFLEX
Liebherr-Verzahntechnik GmbH faced a major challenge: to efficiently manufacture gear hobbing and gear grinding machines in-house. What was needed was a production control system that combined flexibility, efficiency and automation. The solution: SOFLEX – an independent, manufacturer-neutral system that has fundamentally automated and optimised the production process at Liebherr.
Industry 4.0 before it had a name – the original prototype at Liebherr with SOFLEX
Precision is essential in the gear cutting industry. Other important goals were flexibility, high machine utilisation, raw material management and the ability to operate unmanned across multiple shifts. At the same time, Liebherr needed a production control system that could efficiently manage small quantities without compromising reliability and cost-effectiveness.
The original system was compact in design – with only one machine and a small pallet handling system. And yet it was technologically ahead of its time: the original prototype of automated production at Liebherr. Particularly noteworthy: this solution was implemented before the term ‘Industry 4.0’ even existed – and yet it already fulfilled its core ideas at that time: networked production, digital transparency, automated processes.
Modular growth with SOFLEX – from pilot cell to networked manufacturing solution
With SOFLEX as a partner for the production control system, not only was a single project implemented – it also marked the starting point for continuous technological development.
The system grew with the requirements, could be expanded modularly and continues to prove to this day that Industry 4.0 does not begin with big buzzwords – but with courageous first steps and strong partnerships.
What once began as a compact pilot solution has now developed into an impressively complex manufacturing plant.
In addition to the original STARRAG HECKERT machine, two further machining centres from GROB have been integrated into the system. The Liebherr pallet handling system has also been significantly expanded. The system is complemented by three set-up stations, an intelligent material conveyor system and a modern pallet storage rack.
Despite the increased complexity, the overall process remains efficient and clear – made possible by SOFLEX. All components are working together seamlessly under the control of SOFLEX, ensuring smooth operation even for the most complex tasks.
The implemented solution focused on the PHS Pro pallet handling system, a scalable, robust handling system. The SOFLEX production control system, on the other hand, has the task of organising and controlling all production processes within the plant, i.e. planning and organising order processing, controlling the workpiece throughput and the provision of operating resources (tools, NC data, fixtures, etc.) and transmitting the necessary production information to the processing machines.
This seamless networking has increased machine utilization to an impressive 90% and reduced production costs by up to 40%.
SOFLEX also ensures:
- Optimal material management: tracking and efficient use of raw materials.
- Workflow optimization: Ensuring a smooth machining and handling process.
- Paperless manufacturing: Providing digital instructions to operators at set-up stations to ensure error-free processes.
- Real-time tracking: Monitoring the location and status of each workpiece at all times.
A groundbreaking change for Liebherr: doubled production output and significant cost savings
The impact of SOFLEX on Liebherr's production capacity has been groundbreaking. Key results included:
- Doubling of production output: improved efficiency doubled capacity.
- Increased machine utilization: machine uptime increased by 40%.
- Significant cost savings: process optimizations drastically reduced manufacturing costs.
- Less workload: automation minimized manual intervention and allowed employees to focus on higher-value tasks.
A foundation for the future of manufacturing
The SOFLEX production control system continues to serve as a cornerstone solution for Liebherr-Verzahntechnik GmbH. Further enhancements and the migration to a new server environment ensure that the system remains secure and efficient.
For Liebherr, SOFLEX has not only solved a manufacturing challenge - it has redefined the way the company approaches production. By combining advanced automation, seamless material handling and unparalleled flexibility, Liebherr is now well equipped to tackle even the most complex manufacturing tasks with confidence. This partnership is an impressive example of the transformative power of innovation in industrial manufacturing.
