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When the lights go out in a factory, it doesn't always mean a standstill—quite the contrary. At GM Diecron in Griffin, Georgia, the future of manufacturing is bright precisely because the machines continue to produce even when no one is in the room. With the help of EROWA, this medium-sized aerospace supplier has made the leap from traditional CNC operation to becoming a pioneering lights-out manufacturer.
From manual operation to high-tech manufacturing
Starting out as a manual workshop in 1977, GM Diecron has developed over decades into a modern CNC competence center for structural components in aviation, industrial components, and highly complex precision parts. With 30 employees, the company is compact but all the more efficient—especially since the decision to rely on EROWA Automation.
“One employee per machine? That's simply no longer feasible,” sums up the management. The solution: an automated manufacturing system that multiplies productivity while maintaining consistent quality.
The challenge: more output despite a shortage of skilled workers
Like many manufacturing companies, GM Diecron struggled with limited resources in the labor market. New projects were on the horizon, but additional skilled workers were scarce. The answer was obvious: automation. The team at Morris South made the initial contact with EROWA. A visit to an existing user convinced them – and shortly afterwards, the decision was made. Today, an EROWA ERC80 robot with PC210 pallets and JMS process management is in use. Coupled with an Okuma MU4000V, the system achieves around the clock what was previously only possible in single-shift operation: “Machines used to run 8-9 hours a day, now they work 24/7 – without any breaks.”
Lights out – performance on
The figures speak for themselves: the lights-out concept delivers up to 100 additional machine hours per week. And that's with tolerances of up to ±0.002 inches – a level of precision that is easily maintained thanks to EROWA's reliable workpiece clamping. “It's a reassuring feeling to be able to rely completely on the clamping technology,” says the production manager. Part quality remains consistent while output increases. At the same time, employees can work on several projects simultaneously – a clear gain in flexibility.
More than technology – a cultural change
The introduction of automation was more than just an investment in machinery. It was a strategic step toward the future. And it also changed the everyday work of the workforce. Resistance? None whatsoever. “We are a company that embraces change. If you don't change, you stand still. Our employees were enthusiastic from day one,” says the team. Increased efficiency and the new role of employees – away from the classic operator and toward process manager – have a positive effect on motivation and the working atmosphere.
Challenges? Solved together.
Of course, not everything went smoothly. Especially after the initial training, there were still a few hiccups here and there. But GM Diecron reacted quickly, brought the EROWA experts back in – and production was soon running as planned.
Looking ahead
For GM Diecron, the journey is far from over. Year after year, automation is to be further expanded. New spindles, new cells—all with the aim of further scaling production without increasing the workforce. “Our goal remains: more output with the same team. With EROWA, we have a partner who makes this possible.”
Experience has shown that those who rely on automation not only gain in productivity. They also win over the people in the company. Because when machines take over the work at night, it creates space for innovation, further development, and the next success story.
Conclusion: Trust in technology pays off
GM Diecron is the best proof that lights-out manufacturing is not just a promise for the future, but can be a reality today. With a smart automation concept, innovative technology from EROWA, and a team that sees change as an opportunity, a new form of manufacturing is emerging—efficient, flexible, and sustainable. Or as the team at GM Diecron puts it: “Automation helps on many levels. But the best thing is to see how happy our employees are about it.”
