Investing wisely in the future

Challenge and interest
ULS manufactures the components for its laser systems in-house.  The main materials processed are aluminum alloys and INOX steels. ULS has a high mix of parts but low quantities. This required a lot of setup and changeover time, which led to a lot of machine downtime. There are approximately 750 part numbers, and an average production batch comprises 80 to 100 parts. ULS had already standardized fixtures for accommodating multiple part numbers in order to increase spindle time.

In line with its internal guiding principle of continuous innovation, Universal Laser System set itself the goal of producing more efficiently and doing so with flexible automation. Its own recipe for success, based on modular design at manageable costs, was the basis for its search for a suitable automation partner. In September 2021, a manufacturing engineer at ULS first became aware of EROWA. Tools, workpiece clamping systems, and automation were presented during a virtual company tour on YouTube. He was excited by the possibilities and contacted EROWA to learn more. Universal Laser System needed an automation system that was adaptable in terms of workpiece size and modularly expandable. They found what they were looking for at EROWA. Soon after, an EROWA Robot Multi, the ITS148 and PC210 workpiece clamping systems, and the JMS 4.0 process control system were installed on two Haas UMC500 5-axis milling machines.

Preparation during the day, production at night
All orders are now generated and processed via the JMS 4.0 process control system. All workpiece carrier pallets are identified via the EWIS chip system and transferred to the cell via the Robot Multi loading station using the “setup and loading station manager.” This gives the cell manager a constant overview of all order-related data and the productivity of the production cell. With the EROWA Robot Multi automation solution, ULS can now produce continuously at night. During the day, small series are produced and new orders and workpieces are set up and prepared on the appropriate clamping systems for the unmanned shift. The result? Machine efficiency has increased significantly and setup time has been reduced. 
ULS has not only automated its production, but also significantly optimized it. Existing processes were fundamentally rethought and adapted. Above all, the company wanted to reduce the number of times the workpieces had to be re-clamped. This also led to the creative optimization of the clamping devices for machining the parts so that the workpieces could be machined on 5 sides in a single clamping operation wherever possible.

Relief for employees
The introduction of the robot made it possible to operate a fully automated production cell, which also required a change in ULS’s workflow. Since fewer employees are now needed to operate the entire cell, some staff members were able to take on new tasks within the company.
The biggest challenge after commissioning the automated cell, however, was supplying the system with enough work to meet its capacity. Nathan Zerkle adds with a smile that they are happy to have such “luxury problems”.

Experience with EROWA
With its tooling, automation and process control system, EROWA has had a significant impact on ULS’s manufacturing processes and exceeded expectations. “The implementation and commissioning of the cell went quickly and smoothly, and the after-sales support and training were outstanding,” says Zerkle enthusiastically.
Nathan Zerkle’s experience with EROWA highlights the benefits of automation in manufacturing: even a single automated cell can significantly increase the productivity of an entire company. This provides a solid foundation for expanding the cell modularly in the future, according to specific needs.