Merz Maschinenbau GmbH, a specialist in circular knitting machines for the production of medical stockings and compression garments, has taken an important step towards future viability in Hechingen, Swabia. By automating four existing DMG machining centers with the help of a Kuka robot and an intelligent control system from SOFLEX, Merz has succeeded in significantly increasing efficiency and quality.
Many challenges - clear objectives: 24/7 operation for greater productivity
The project objectives were clearly defined. Merz wanted to increase quality, flexibility and productivity, minimize downtime and shorten delivery times. At the same time, it was important to ensure easy integration of the automated solution into the existing IT infrastructure and to meet ergonomic requirements at the workstations.
Prior to automation, production at Merz was characterized by manual processes, which led to longer set-up times and sub-optimal utilization of the machining centers. It was difficult to maintain productivity at a competitive level, especially with smaller batch sizes. Added to this was the desire to enable continuous 24/7 operation in order to meet the increasing demand for the high-quality products.
![[Translate to English:] Merz Automation](/fileadmin/_processed_/f/d/csm_MERZ_MachineAutomation_1833_98b268b980.jpg "[Translate to English:] Merz Automation")
SOFLEX: The turn-key supplier for automation solutions
Merz commissioned the companies SOFLEX and wbt to implement the automation solution. A Kuka KR 500 R2830 F robot, which is specially designed for high loads and adverse environmental conditions, was chosen. The robot was mounted on an 18-metre-long linear unit in order to efficiently operate the four adjacent DMG machining centers.
The system transports machine pallets and raw materials between the set-up stations, storage areas and processing machines. The SOFLEX control system was seamlessly integrated into Merz's IT network to ensure automatic provision of NC and tool data and further reduce downtime.
Thanks to close cooperation between SOFLEX and wbt, the interfaces were defined at an early stage and the software and robot system were extensively tested before the actual integration. After just a short training period, Merz employees were already working safely and efficiently with the new solution.
Why the automation of existing machines pays off
The automation solution has exceeded all expectations at Merz. Thanks to the optimized machine utilization and the possibility of 24/7 operation, productivity has increased significantly. The shorter delivery times and increased adherence to delivery dates led to improved customer service.
The solution also increased the quality of the products and ensured a sustainable improvement in internal processes. The use of the robot also helped to optimize production processes by automating repetitive manual activities.
Merz Maschinenbau was not only able to save costs through automation, but also position itself as an innovative and reliable partner on the market.
The automation at Merz Maschinenbau is an outstanding example of the potential of automation to fundamentally change traditional production processes. The successful cooperation of all partners has led to a significant increase in productivity and quality and laid the foundation for future growth.
Since the SOFLEX control system has been in use, 24/7 production has become a reality for us. Together with SOFLEX, we have automated existing machines. A robot system takes over the automated provision of workpieces and storage of our raw material. Thanks to the SOFLEX control system, we know exactly what preparations we need to make with regard to tools, devices and NC programs so that we can also produce in unmanned shifts.
Mr. Siegfried Carl Keck
Managing Director
