Unmanned loading and unloading of milling machine increases efficiency and productivity

At KS Metaalwerken in Vliermaalroot, the map of automation is being drawn in full force to increase efficiency and productivity on the shop floor. Kris Swerts' company was one of the pioneers in the automation of turning and is now continuing this evolution to milling as well. For example, they recently invested in a Robojob Tower for the automatic loading and unloading of the Hermle C250 milling machine. Thanks to this high-level automation with FANUC robot, the company can now produce unmanned for up to 72 hours, ideal for an efficient production process during the day, night and weekends.

'Very strong in turning and milling' - that is what can be read in large letters on the homepage of the website of KS Metaalwerken, the bvba that Kris Swerts started in 2001. "In the beginning the focus was on sheet metal working and welding, but gradually we began to specialize more and more in CNC turning and milling - 2D, 3D and five-axis. By working closely with other specialized companies, laser cutting is also among the possibilities," says COO Ronny Bogaers. "In 2016, we moved to our new premises and the machinery was significantly expanded, with mainly lathes and milling centers, but also a wire EDM, a start-hole EDM and a welding robot. Another important asset is our dynamic and driven team of employees - 13 full-time employees in total - with a great drive for innovation in all areas: software, special mills and other tools, own developments....Tot finally, we also have a strong reputation because we do reverse engineering and think along with the realization of each project, taking into account the manufacturability and costs. In short: there is a lot of knowledge in-house and we don't shy away from any challenge."

Automation of turning and milling work

Efficiency and productivity are priorities at KS Metalworks. That is why we continuously invest in machines, tools, software and automation. When the company connected three industrial FANUC robots to the lathes about ten years ago, they were immediately one of the pioneers in automating the turning process. 

"Meanwhile, production in our rotary department runs continuously: during the day, at night and on weekends. This allows us to respond flexibly to our customers' requests, even if they are extremely urgent," the COO continues. "Meanwhile, we also continue to invest in our milling department. For example, three years ago we purchased a five-axis Hermle C 400 with a course of 850 x 700 mm and recently added a C 250 with a course of 600 x 600 mm from the same German machine builder. Here, too, we chose to automate, as a RoboJob Tower takes care of automatic loading and unloading of the machine."

Bart Vercruysse, area sales manager at RoboJob, explains, "Our Tower is a revolutionary total solution that allows users to produce autonomously and unmanned, both serial work and single pieces. This loading and unloading system with a height of 4.6 meters includes space for at least 8 fixtures and at least 15 drawers for raw and finished parts. This creates a lot of capacity in a limited floor space. The "brains" of the Tower are in the software and its user interface, which allows one to set everything in motion quickly and easily. The elevator retrieves the right tray at the right time, after which the industrial FANUC robot with servo gripper can load the workpiece into the machine and take it out after machining. One can also easily switch between workpiece and pallet loading. In this way, the Tower can be prepared to continue production for 72 hours at a stretch, improving efficiency and productivity on the shop floor."

Looking to the future

Automation remains the code word for KS Metaalwerken in the future as well. Today, three lathes and a milling center can already produce unmanned, but this automation will certainly be expanded. "In this respect, RoboJob is a 'partner in crime' for us, with whom we have built a strong bond of trust thanks to their attention to product quality, support and service", Ronny Bogaers indicates.

Marketing manager Steven Craenen of Robojob concludes, "Our story with KS Metaalwerken actually has two sides. After all, the manufacturer is not only a customer of ours, but also a very important supplier of parts for our products. We can thereby always count on accurate products with the highest degree of finishing as well as a rock-solid service." ■