The future is automated

The Komax Group's machines focus on processes such as measuring, cutting, stripping, contacting, and bandaging cables, as well as assembling connector housings. Standard models and customized systems such as stripping machines and fully automatic crimping machines are complemented by a comprehensive range of quality assurance modules and networking solutions for the safe and efficient production of cable assemblies. The Komax Group also manufactures systems for testing cable assemblies. Around three-quarters of the Komax Group's sales are generated with customers in the automotive industry. This industry is currently undergoing tremendous change: electromobility, digitalization, and autonomous driving are megatrends that demand increasingly complex cabling solutions and thus products from the Komax Group.
Through continuous development and close cooperation with its customers and partners, the Komax Group strives to optimize and improve automated cable processing. This is also reflected in its collaboration with EROWA. “The conviction that continuous innovation is the best solution for future requirements unites the two innovative Swiss companies,” explains Alois Bättig, Sales Manager at EROWA Switzerland.

As a market and technology leader, the Komax Group sets high standards for its own products – which is why it has its own in-house manufacturing facilities. "This enables us to respond quickly to constantly changing challenges. As we expand our product range, we are constantly producing new parts. But digitalization in manufacturing also presents us with new challenges. We are convinced that automated manufacturing offers major advantages here: what we produce today, we process next week, without high storage costs,“ explains Christian Schärer, Director of Mechanical Manufacturing at Komax in Switzerland. This flexibility also means that production must run at 100% capacity. ”Process reliability is our top priority. We cannot afford mistakes. And we have been relying on EROWA for decades – in partnership and with great success," Christian Schärer continues. 
In 1998, the first milling machines at Komax were equipped with the EROWA UPC and ITS 148 workpiece clamping systems, and the first EROWA robot was put into operation in 2000. Since then, additional handling devices have been added, such as the EROWA Robot Multi on a Mikron HSM 600 U, an EROWA Robot Compact on a Geibel and Hotz FS 640, and the EROWA JMS 4.0 ProductionLine process control system.

In 2022, the first step was finally taken to replace the aging Mikron facility. “We defined clear requirements for the new production cell, and our goal was to take the experience and advantages gained from the ongoing processes on the existing facilities and integrate them into the new cell for further optimization”:

• Production costs should be reduced by over 10%.
• Machine capacity should be increased by 20%.
• Ultimately, a spindle time of over 6000 hours per year should be achieved per machine.
• Maximum process reliability must be guaranteed by the machine and handling.
• Individually clamped workpieces in 5-axis machining, as well as large pallets with multiple clamping, must be able to be machined in a mixed and flexible manner.
• Increase flexibility in order planning between prototypes, individual parts, small series, and large series.
• High base load due to fixed articles.
• Use of existing equipment such as clamping towers and vices.
• Automation and workpiece clamping systems that meet these criteria.

Investments were made in a Heller HF 3500 5-axis machining center and an EROWA Robot Dynamic 500 Linear (on a 9-meter rail with 91 magazine slots). Machine pallets are changed using the robot, or MTS 400 pallets and ITS 148 pallets via adapter pallets. The new production cell is supported by the EROWA JMS 4.0 process control system for control and data transfer.
As the JMS 4.0 software has already been in use for years on the Mikron milling machine and on a Geibel & Hotz, employees have no problem operating the process control system. Schärer adds: “The software helps us a lot to organize and keep track of all production data. It is very intuitive to use.” The main materials processed are steel and aluminum, and existing production orders are continuously reprogrammed and optimized. Batch sizes range from 5 to 100 pieces and part sizes from 50 x 50 x 50 mm to 300 x 250 x 110 mm. "We secure large workpieces and clamping devices on MTS pallets. We palletize smaller workpieces on the EROWA ITS 148 system. Using adapter pallets, these workpiece carriers are integrated into the system throughout. This allows us to keep changeover times to a minimum," says Christian Schärer.

Increasing productivity while maintaining very high quality
Following detailed planning, the new production facility went into operation in October 2022. And we are well on the way to exceeding the required targets. The automation system is ready for 24/7 operation. “The EROWA clamping systems and the palletizing of the workpieces are crucial for ensuring and optimizing flexibility in automation—in order to increase productivity and maintain Komax's very high quality standards,” explains Schärer.

Mastering challenges together
The digital networking of the entire production process and the entire company represents a major challenge. “We are convinced that the only way forward is digital and automated – but of course that's not always easy,” explains Schärer. “Innovative and long-standing partners help us to find the right solutions for the challenges we face.” Komax benefits from EROWA – and vice versa. In October 2023, the system was expanded with a second Heller machine and an extension of the robot rail with additional magazine spaces and a loading station. “We are already looking forward to the ERD 500 being even better utilized – after all, it is here to work,” adds Schärer with a grin. However, it is clear that Komax will continue to invest in its own automated production in the future. “Because the future is automated,” Christian Schärer is convinced.