Bunorm Maschinenbau, a Swiss company founded in 1965, started with basic welding constructions before transitioning to machine engineering. Today, the company specializes in machining and special purpose machinery construction, with a particular focus on complex and large welded constructions with mechanical processing. They offer the production of small and large individual parts, small series, complete assemblies, and systems.

Four years ago, Bunorm Maschinenbau joined the Swiss Factory Group to strengthen their presence in the Swiss market. The company employs about 100 people across two locations with a total production area of 10,500 sq. m. (113,021 sq. ft.). As a comprehensive welding solution provider, they are committed to the consistent modernization of their machine park.

The challenge: programming diverse complex welds efficiently with quality

With the significant flexibility of their machinery, Bunorm Maschinenbau can handle machine parts ranging from 100 mm to 18,000 mm. However, the necessity to alternate between different products and adjust to fluctuating demand patterns can result in inefficiencies, extended lead times, and heightened operational costs. These are typical production challenges encountered by manufacturing companies in a high-mix, low-volume environment. To ensure high efficiency and quality in their production process, Bunorm Maschinenbau aimed to enhance their robot programming efficiency and transition beyond manual programming.

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau, has been with the company for over a decade. Starting as an apprentice tasked with welding on the production line, he has now become an international welding specialist and the head of non-destructive testing. With 10 years of robot programming experience, he is also in charge of managing Yaskawa welding robots and programming for special projects, such as aviation.

Complex welding capabilities enabled by offline programming

Offline programming (OLP) allows complex individual parts, as well as series parts, to be programmed and optimized in advance on the software outside of the production.

The company can weld constructions up to 20 tons and machine constructions up to 60 tons. They have two welding robots from Yaskawa, both programmed with Visual Components OLP. The first robot Yaskawa YRC1000 can weld workpieces up to 7 m (22 ft) in length, 1.5 m (4.9 ft) in width, and up to 3.5 tons. The second robot Yaskawa DX200 can handle workpieces up to 2.5 m (8.2 ft) in length and 1.5 m (4.9 ft) in width, up to one ton of weight.

OLP can be a valuable tool in projects that involve not only extensive robotic welding, but also partial robotic welding. One example is the production of a machine designed to seal tunnels with foil to prevent water ingress. A major part of this machine was robotically welded with the robot programmed using OLP.

With Visual Components OLP, multi-layer welding seams can be programmed easily, making it possible to handle complex welding tasks. The software also simplifies troubleshooting robot program for reachability and collision issues.

Visual Components has a huge library. The list of post-processors you’re seeing on my screen right now is just what you get for free (included in the license). I believe they have even more based on what I know, but I’m just a customer. I think Visual Components is compatible with every robot brand.

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau

Improving weld quality and production efficiency

Offline programming makes it possible to implement measuring operations very easily, leading to an increase in weld quality. The software enables efficient operation of the welding robot and minimizes downtime.

Even for small batch sizes, such as 15 identical pieces, offline programming proves to be more efficient than manual programming. With online programming, it would take at least two days to program the robot for such a task using the teach pendant. With offline programming, the same program can be completed in half a day, reducing programming time by 75%.

What I will show you is how I post-process the program… you can see that with these 3 statements, I just created 41 lines of program. I could have written 41 lines of code on the controller, but this is my way of showing you how efficient Visual Components OLP is.

Without Visual Components OLP, we wouldn’t consider it to be efficient enough with the robot if we were to program it by hand on the controller.

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau

Getting started with offline programming

If you are a manufacturing production manager considering the adoption of OLP software, D’Angelo recommends testing the software if possible. Visual Components provides the opportunity for potential users to evaluate our software, request a personalized web demo here to get started. He also highlights the excellent support provided by Visual Components, citing his own experience of learning to use the software.

“Vidisha, an engineer from Finland, flew to Switzerland. She measured the machine and the whole jig from the robot. She created the cell for me and simultaneously taught me how to use it during her visit. These three days provided a good enough foundation for me to further improve my skills. Whenever I had a question, I could always reach out to Vidisha via call or email, and she responded very quickly. The support from Visual Components is really, really great.”

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau

Bunorm Maschinenbau’s case study showcases how a parts supplier can utilize offline programming to address complex welding projects, achieving substantial gains in efficiency and quality, even within a high-mix, low-volume production setting. With a commitment to innovation and a focus on efficiency and quality, Bunorm Maschinenbau continues to strengthen its standing as a leader in the manufacturing and assembly of complex and large parts in the Swiss market.

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post Mastering complex welding: Bunorm Maschinenbau’s quality and efficiency boost with Visual Components OLP appeared first on Visual Components.

The Institute of Production Science at KIT focuses on application-oriented research of the production of tomorrow: from global, resilient production networks to the breathing factory with highly productive plants and innovative business models to quality assurance. Specifically, practical tools are developed for industry, which are then translated into entrepreneurial success.

BENTELER Group, a metal process specialist, produces safety-relevant products, systems, and services for the automotive, energy, and machinery industries worldwide.

BENTELER Automotive is a development partner of leading automotive manufacturers. With 19,000 employees and around 70 plants in over 20 countries, the division develops customized solutions: Components and modules for chassis, body, engine, and exhaust systems as well as innovative solutions for electric vehicles.

Automatic assembly and welding of a car axle from sheet metal parts

As part of a research project, an assembly line from BENTELER Automotive was to be analyzed. In this assembly line, a passenger car axle is assembled from sheet metal parts. The production of the sheet metal parts, i.e., pressing and punching, is not considered here; the focus is solely on the assembly and welding of the sheet metal parts.

The assembly line consists of 5 welding cells and one cell for laser cutting. The cells are connected by handling robots; the line also includes the supply of the sheet metal parts and the removal of the final product.

In each welding cell, a different number of sheet metal parts are welded into an assembly. This intermediate product is transferred to the following cell and then welded with further components to form a new assembly. With the help of rotary tables, processing, loading, and unloading partly take place simultaneously.

Assembly lines of such complexity cannot be planned manually

When planning such an assembly line, numerous requirements must be considered. The rotary tables and handling robots must be arranged in such a way that optimum accessibility is ensured, i.e., that the distances and thus the cycle times are as short as possible. Collisions must be avoided at all times. In addition, the processes must be coordinated in such a way that processing and loading/unloading can be carried out in parallel. Finally, the welding line must be supplied with the sheet metal parts and the end products must be removed.

In the past, such assembly lines were planned manually and with the help of Excel spreadsheets. However, such complex production systems cannot be modified or adapted in a short time; moreover, a realistic representation of the assembly line and its processes is missing.

To enable more precise planning of production systems and to reduce the time-to-market, it is necessary to use modern software for factory planning and simulation. The Institute of Production Science has chosen Visual Components for this purpose.

Professional software for factory planning and simulation

At Visual Components, we are proud to be recognized as one of the world’s leading providers of 3D factory design and simulation solutions. Our software includes an extensive library of predefined factory components, empowering planners to design, plan, and simulate production facilities efficiently. Users can create digital twins of everything from individual machines and production lines to entire factories. These digital twins are essential tools that facilitate meticulous planning, optimize production processes, and enable virtual commissioning, ensuring that our customers are well-prepared for real-world implementation.

Based in Espoo, Finland, our solutions have a global footprint and are utilized across a diverse range of industries, including industrial machinery, automotive, packaging, and logistics. Our software is available in various versions that cater not only to large corporations but also to smaller enterprises through both purchase and rental options. This flexibility helps businesses of all sizes leverage our advanced simulation capabilities.

Furthermore, we offer particularly attractive conditions for educational institutions, supporting the next generation of engineers and industry professionals in gaining hands-on experience with industry-leading simulation technology.

Numerous CAD interfaces and a comprehensive catalog of factory components

The models of the components to be welded can be imported into Visual Components in native CAD format or as JT or STEP files. The data of numerous robots from all leading manufacturers, including detailed kinematics, are available in the library, the eCatalog of Visual Components. In total, our eCatalog contains more than 3,000 predefined components, such as machines, conveyors, and racks which can be used out-of-the-box to create factory models. If a component should not be available in the eCatalog, e.g., a special robot gripper, it can simply be modeled in Visual Components, including its kinematic properties, and then used by any robot.

Visual Components very accurately represents the components and processes, including all details. BENTELER Automotive is enthusiastic about the many possibilities that Visual Components offers for factory planning.

Mr. Louis Schäfer, M.Sc., academic assistant at the Institute of Production Science

The stations can be linked as desired by simple drag-and-drop

All stations of the welding system were set up in Visual Components. The modular structure facilitates future modifications because new concepts of the welding system can easily be set up and quickly tested and optimized via simulation. It is also possible to extend the model into a digital twin after the physical welding line has been built. Such a digital twin behaves exactly like the real system. A digital twin saves a lot of time and costs in development, optimization, and commissioning.

Validation of robot programs in terms of reachability and axis values

According to Mr. Schäfer, the Institute of Production Science also intends to use Visual Components for the validation of robot programs in terms of reachability and axis values. The modularization allows new versions of the production line to be set up accurately in a short time. Other problems can also be solved via simulation, e.g., the identification of bottlenecks in the production flow or the evaluation of differences between automatic and manual handling. A digital twin is also being considered, i.e., the integration of real process data into the model.

In summary, Mr. Schäfer states that Visual Components offers enormous potential for a wide variety of simulation-related tasks. The user-friendly system allows a detailed analysis, as one can represent even very complex issues. In addition, working with Visual Components is a lot of fun. The user forum provides a lot of support: In case of questions, helpful solutions are quickly provided by the large user community.

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post BENTELER rolls out the production technology of tomorrow with the help of Visual Components appeared first on Visual Components.

In modern furniture production, where very large quantities are manufactured, the efficiency of packaging systems at the end of the production line is crucial. A prime example of such capability is demonstrated by Wächter Packautomatik, a specialist in this area. Their advanced packaging system is not only adept at handling high volumes, with the capacity to package about 20 cabinets per minute, but it also showcases remarkable versatility.

Given the diverse range of furniture variants, the packaging process must transcend individual formats to encompass all cabinet sizes, from the smallest to the largest. And the lines must not only pack the cabinets, but they must also perform the folding and closing of the cartons and the palletizing of the finished packages. 

In addition, packaging lines need to take up as little space as possible. The systems must operate with maximum automation, both during operation and when changing formats. And finally, they must be planned to be fail-safe and equipped with redundant process options.

A flexible packaging solution using 15 industrial robots 

An international furniture manufacturer offering furniture for self-assembly at home asked Wächter Packautomatik for a solution to pack large production volumes of furniture. A team from sales, mechanical and electrical design, and automation at Wächter Packautomatik offered a packaging solution using industrial robots because they knew from experience that only robots provide the necessary flexibility and high availability.

The team developed a concept consisting of 15 robots divided into 7 individual cells. The packaging line is supplemented by two carton folders at the start, which fold a tray from a flat carton blank, and two lidding machines at the end of the line, which seal the filled cartons. The finished product is then stacked on pallets.  

A packaging cell with two robots was first set up as a prototype to test the processes and functions in real life. After this prototype passed all tests and fully met the customer’s expectations, the planning of the entire line was started based on the experience gained.

A digital test is faster than a physical test 

A particular challenge in this project was the large variety of product variations. If all variants had been tested using the real robot cell, it would have been very tedious and time-consuming. Therefore, a solution for factory planning and simulation was required, which would allow the modeling and analysis of a digital twin of the packaging plant. A digital twin behaves like a real plant; it can save a lot of time and costs in development, optimization, and commissioning. 

Wladimir Krieger, Robotics Engineer, working in the automation department at Wächter Packautomatik and being responsible for the software-related commissioning and optimization of machines and robots, chose Visual Components. 

How the cabinets get into the cartons

The cabinets to be packed, consisting of walls, doors, and shelves, are stacked on pallets and fed to the robotic cells from two sides via a complex, fully automated conveyor system. The pallet positions are located on the left and right of the packaging line. Two robots remove the required number of products and place them on an alignment table above the cartons. Then they are picked up by another robot and inserted into the folded cardboard case.  

With this setup and two cardboard cases filled side by side in parallel, the system can pack 20 boxes per minute, from small shelves to large cabinets. One side of the packaging module can be prepared for the following format without interrupting the ongoing packaging process on the opposite side. Format changes as well as filming, labeling, and removal of the remaining parts can thus be done without time pressure. 

Visual Components facilitated a very high level of automation

Wladimir Krieger from Wächter Packautomatik describes the reasons why he finds this project so outstanding:

Our packaging plant achieves a level of flexibility and automation that has never been seen before on the market. Visual Components’ software simplified the feasibility analysis and accelerated the modeling processes. Thanks to modeling, we were able to try out numerous settings directly on the digital model. And as a sort of bonus, we were able to train the operators even before the real plant was completed, which accelerated commissioning.

Wladimir Krieger, Robotics Engineer, Wächter Packautomatik

Due to the large number of variants and the high throughput with the corresponding short cycle time, Wächter Packautomatik had to develop a new type of concept for the packaging machine. Visual Components was initially used to communicate and explain the new concept to the customer. Later, in parallel with first prototypes, Visual Components made it possible to reliably plan material flow, robot movements, and cycle times with very little effort. 

Convincing results – for Wächter Packautomatik and their customer 

For Wächter Packautomatik and its customers, the digital twin built with Visual Components is of great benefit, because the individual processes and their interrelationships can be very easily clarified and presented understandably. With just a few mouse clicks, the product to be packaged, and the corresponding robot cell can be switched to another variant. This saves a lot of time when testing, optimizing, and demonstrating the individual packaging processes, and the digital twin also saves valuable resources. 

Wladimir Krieger from Wächter Packautomatik emphasizes the advantages of the digital twin:

Unlike with previous projects, the processes no longer had to be tested at the physical system. Instead, even the most complex processes were displayed reliably and quickly in digital form. We also simulated the machine settings for the different formats with Visual Components.

Wladimir Krieger, Robotics Engineer, Wächter Packautomatik

Mr. Krieger is also responsible for on-site customer training: “Another advantage is the training of the operating personnel on the digital model. The machine operators knew the settings of the system at an early stage and could start directly. This was possible thanks to the model in Visual Components.” 

Wächter Packautomatik will continue using Visual Components as an important tool in the areas of process planning, validation and visualization. Due to the growing demands of the market, packaging plants will become even more complex in the future. Visual Components will make it much easier to map this complexity in engineering and present it to customers. 

About Wächter Packautomatik 

Wächter Packautomatik manufactures packaging machines for the food, flooring, and furniture industries and numerous special solutions in Bad Wünnenberg-Haaren, North Rhine-Westphalia, Germany.  

Mr. Krieger works in the automation department at Wächter Packautomatik and is responsible for the software-related commissioning and optimization of machines and robots as well as customer training. He also provides internal support for quotations, feasibility studies, and project planning of robot systems. 

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post Packaging perfection: navigating variations in furniture packaging with Visual Components appeared first on Visual Components.

Berlin Gardens, established in 1988 in the heart of Amish Country, Ohio, began as a humble greenhouse, selling plants and flowers to the local community. This early period instilled a deep understanding of craftsmanship and community values, which would later become the bedrock of their business philosophy.

The transition to manufacturing outdoor furniture marked a significant shift in their business model. Their focus on easily shippable, stylish furniture designs quickly set them apart in the market. Under the leadership of Sam Yoder since 2008, the company has expanded its workforce to 250. The company has evolved to specialize in manufacturing high-quality outdoor poly furniture and backyard structures, employing state-of-the-art machinery alongside time-honored crafting techniques.

Understanding the competitive landscape

In the last 15 years, the poly furniture industry has transformed significantly. What was once a novel concept has now become a competitive and bustling market segment. Berlin Gardens has not only kept pace with this change but has also established itself as a key player.

The company’s unique approach focuses less on external competition and more on internal customer service – prioritizing the well-being and satisfaction of its employees. This philosophy underlines their belief in doing business with integrity, including fulfilling promises such as on-time shipping, which in turn enhances external customer service. Sam Yoder’s vision incorporates a Lean Manufacturing approach, constantly refining processes to balance the pursuit of quality with the need for speedy fabrication.

In line with this pursuit of quality with the need for speedy fabrication, the integration of Visual Components Robotics OLP in Berlin Gardens’ welding of aluminum fixtures marked a significant step in the right direction.

Derrick Yoder, the Aluminum Production Manager at Berlin Gardens, oversaw the transition to more efficient and precise automation in processes like arc welding. The crucial first step in this transition was the initial setup and calibration of the robots, expertly handled by specialists from Mach Machines, Partners of Visual Components based in Ohio, USA. This essential groundwork, complemented by Mach Machines’ comprehensive training on the software, provided Berlin Gardens with a robust base for future utilization of Visual Components Robotics OLP in other processes.

Following this foundational setup, the focus shifted to the advanced functionalities of Visual Components Robotics OLP. The main robot programmer at Berlin Gardens, an Amish worker, found the software exceptionally user-friendly and efficient. With just a couple of clicks, he could program multiple robot paths for the Yaskawa robot cell, all on a single platform. Not only that but the knowledge could be stored in the software for future robot programmers to reuse or optimize.

The biggest difference was the amount of points programmed by simply selecting a joint in the software. And it’s not all simple movements. We have different fixtures where it takes a bit of maneuvering to place the welds, but the software handles them just fine with accuracy. When programming point to point with the pendant before everything was very repetitive – spending hours manually moving the robot. Even then it’s hard to stay consistent with different moves with the robot which can cause inefficiencies on wasted movements. With the software everything can be controlled with the same movements each time.

Derrick Yoder, Aluminum Production Manager at Berlin Gardens

The move from traditional, manual programming to an automated system not only streamlined operations but also represented a significant leap in the company’s technological capabilities and digital transformation. Visual Components Robotics OLP found its critical application in programming welds for aluminum fixtures, essential components of the company’s outdoor furniture. This software enabled the programming of complex weld paths and optimized robot movements, leading to significant efficiency improvements.

The shift from manually programming each point with a pendant to selecting joints through the software reduced repetitive tasks, ensuring consistency and accuracy. This change was not just about saving time; it was about enhancing the quality of each piece of furniture produced, maintaining Berlin Gardens’ reputation for excellence. The feedback from the team has been overwhelmingly positive. Employees have noted the dramatic reduction in programming time and the enhanced consistency in the quality of robotic welds, leading to a more efficient production line and improved job satisfaction.

Quantifying the impact

The impact of Visual Components Robotics OLP on Berlin Gardens’ operations can be quantified by remarkable efficiency gains and cost savings. Programming processes that once took days now take mere minutes. For example, programming a complex fixture that previously required a full 13 hours to get into production can now be completed in under 3 hours. An 80% reduction in programming time! This drastic reduction in programming time has not only led to significant labor savings but has also enhanced the overall operational agility of the company. Looking ahead, Berlin Gardens is enthusiastic about further utilizing Visual Components Robotics OLP in its operations. The company is exploring potential expansions in areas where automation can enhance efficiency even further.

Just for example one of our fixtures would have taken a full 13 hours of programming to be ready for fabrication but with the software we can be up and running within 3 hours. That gives you a small glimpse into the labor saved not to mention the efficiency of how the program then runs.

Derrick Yoder, Aluminum Production Manager at Berlin Gardens

Berlin Gardens’ case study is a compelling example of how a company can successfully integrate modern technology into traditional craftsmanship. By embracing technological innovation and maintaining core values, Berlin Gardens has not only enhanced its operational efficiency but has also solidified its position as a leader in the outdoor furniture industry.

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post Welding innovation and tradition: how Berlin Gardens forges ahead with Visual Components Robotics OLP appeared first on Visual Components.

Mazak UK’s Project Engineering Centre in Worcester, England, faced several challenges in their quest for operational excellence. One significant hurdle was the complexity of explaining and planning around their Palletech system, a highly advanced, modular flexible manufacturing system designed to optimize the efficiency of Mazak’s CNC machine tools. This system is characterized by its modularity, allowing for customization according to specific manufacturing needs. It can include multiple machines, robotic arms for material handling, and storage solutions, all working in unison to streamline production.

However, the complexity of the Palletech system lies in its extensive customization options and the intricate interplay of its components. This complexity posed a significant challenge for the team at Mazak UK, as traditional 2D drawings and explanations were insufficient to convey the full capabilities and configurations of the system. The detailed nature of the system, with its numerous components and possible configurations, made it difficult for clients to fully grasp the extent of its functionality and efficiency without a more dynamic and interactive representation.

The search for a solution led Mazak UK to Visual Components, promising not just an upgrade in how they presented their solutions to clients, but also a restructuring of their internal processes, particularly in CNC machine programming and CAD/CAM integration. The decision to implement Visual Components was driven by its compatibility with Mazak’s existing infrastructure and its potential to significantly cut down on the time and resources spent on project planning and execution.

With Visual Components, Mazak UK achieved a remarkable improvement in the speed and efficiency of their proposal generation. Where it once took weeks to prepare and present a proposal to clients, Visual Components enabled the team to accomplish this in a fraction of the time.

Previously, we were looking at around about 4 days to turn a proposal around, and currently (with the help of Visual Components) we can probably fire one out in about half an hour.

Stephen Smith, Project Manager at Mazak UK

Client engagement and understanding with 3D visualization

The 3D visualization capabilities of Visual Components marked a paradigm shift in how Mazak UK engaged with its clients. From high quality video and images to 3D PDFs, the software’s ability to present complex manufacturing systems in an easily digestible 3D format meant that clients could better understand the proposed solutions.

The introduction of Visual Components at Mazak UK’s Project Engineering Centre enabled the engineers to adopt a more client-centric approach. This approach, focusing on involving the client in the design process, led to improved client relationships and satisfaction. Additionally, the integration of Visual Components into Mazak’s workflow enhanced operational efficiency not only on the manufacturing floor but also in sales, project management, and client servicing. The software allowed for a more integrated approach to project management, connecting different aspects of the operation.

Customization for enhanced project delivery

One of the standout features of Visual Components that Mazak UK capitalized on is its robust customization capabilities. This aspect of the software played a crucial role in enhancing their manufacturing process optimization. The ability to tailor each component and simulation to meet specific project requirements offered Mazak a significant edge in both design and execution.

Key aspects of customization include:

• Modifying 3D models: Engineers at Mazak UK were able to alter and fine-tune 3D models within Visual Components, ensuring each component accurately represented their real-world counterparts.
• Scripting for advanced functionality: Utilizing the open API and Python scripting in Visual Components, Mazak added custom functionalities to their models. This approach allowed them to simulate complex manufacturing scenarios and machine interactions that were previously challenging to conceptualize.
  Stephen Smith, Project Manager at Mazak UK, explains, ‘Given that everything can have a Python script behind it, we’re able to attach interfaces to these modules, and we’re able to make sure that they clip together, first of all, in the right place. Or secondly, if they can’t clip together physically, they won’t in the software world.” This level of detail in scripting enhances the precision and reliability of the simulations.
  In addition, Mazak has created an automated solution that creates a bill of materials from the layout with one click of a button, further speeding up the proposal process.
• Adapting to client specifications: Customization also extended to adapting designs based on specific client requirements. By tweaking models and simulations, Mazak could present tailored solutions that resonated more effectively with their clients.

To further enhance planning and operational efficiency, Mazak UK incorporated statistical analysis from Visual Components which can be displayed visually in software as pie charts and line graphs. Statistical reports can be generated to assist in planning, to check on things like ensuring that manually loaded cells are optimized so that the operator is not overworked, for example, and the machines are not left idle. In some instances, this has allowed for planning of how operators carry out other duties without affecting the output of the cell, showcasing to clients a flexible and efficient use of human resources.

Mazak UK’s adoption of 3D simulations in their customer communications serves as a compelling case of how digital transformation can propel a manufacturing company to new heights. The efficiency gains, enhanced client engagement, and operational improvements exemplify the potential of embracing simulation tools like Visual Components.

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post CNC-ing clearly now: boosting proposal speed and client understanding with Visual Components at Mazak UK appeared first on Visual Components.

This latter situation was one that Invio Automation, an industrial automation systems integrator, encountered recently. Invio’s Factory of the Future Consulting team was commissioned by a building products OEM that assembled windows to help evaluate how to increase throughput while maintaining or reducing overall direct labor.

Invio’s consulting team began its process by partnering with the customer team to develop a long list of potential ideas. From there, the Invio team needed to whittle down the long list of ideas to a small number of potential, highly impactful projects. This meant exploring multiple concepts with the client, evaluating each idea’s ROI, and pitching the shortlist of proposals to business managers. In the past, this process required intensive effort and often utilized tools like PowerPoint to communicate nascent ideas visually. For this project, however, Invio Automation turned to Visual Components’ manufacturing simulation software to accelerate its ideation process.

The resulting proposals were produced in less time, evaluated more rigorously, and garnered a higher level of client support than had been seen in previous projects. This case study explains how that was achieved and how Visual Components software contributed to the success of the undertaking.

Individual sections address:

• Solving complex engineering problems for the largest industrial companies in the world
• Finding solutions for an increase in demand
• Automation and the role of Visual Components
• Benefits of Visual Components in identifying potential automation cases
• Simulating Automation in window manufacturing

Solving complex engineering problems for the largest industrial companies in the world

In many industries, manufacturers are under pressure to improve quality and cut costs. An additional and widespread challenge is labor shortages stemming from high levels of retirement and difficulties in recruitment. For many manufacturers, including the one discussed in this case study, their biggest challenge is satisfying a high level of demand.

Most manufacturers understand automation is a way to tackle these problems. For some, automation means robots and CNC machines. Others are investing in autonomous guided vehicles (AGVs) or autonomous mobile robots (AMRs). And many are looking further into the realm of hyper-automation where all aspects of the business are candidates for improvement.

When manufacturers seek step-change process improvements, they often start by engaging with an industrial automation system integrator. Invio Automation is one of the larger integrators in North America and offers an extensive range of capabilities. AMRs, custom assembly cells, robotic automation, machine vision, and web handling applications are just some of their areas of expertise.

Invio works with clients in industries such as medical devices, renewables, automotive, and building products. A common problem for many clients across all these environments is that they either do not know what automation could do for them or they are unsure of where to start on the process of automating their existing, and often highly manual, operations. For these businesses, Invio offers its Factory of the Future Consulting service.

The Factory of the Future process starts with an on-site workshop to review the client’s existing manufacturing operations. Subject-matter experts and others from Invio Automation convene at the customer’s facility to identify opportunities. After the on-site workshop, Invio engineers develop 3D concepts and simulations. Through a high degree of collaboration with the client over a period of just a few weeks, a list of initial target projects emerges, and the basis of an ongoing relationship is formed.

Finding solutions for an increase in demand

Manufacturing windows for the construction industry is big business. According to a report published by Research and Markets, the global windows market is expected to grow by ~9% CAGR through the end of the decade.

These windows are engineered for repeated opening, rapid operation, and hostile environments. Many have security features, and some are power-operated. Customers demand a wide range of shapes and sizes and a high level of customization. Consequently, producers making these types of windows have deployed very little automation to date.  

Invio Automation was commissioned by a window manufacturer to lead a consulting engagement focused on automating processes that were historically highly manual. This manufacturer’s processes have remained largely unchanged over the last decade and consisted of manual fabrication steps, manual assembly, unstructured material handling, and more. Facing increasing demand for their products, leadership was very aware that things had to change to keep up with the growing demand. For Invio and the customer team, the primary goal of the study was to identify and define projects that would enable a substantial increase in output without adding labor. Quality improvements and other indirect cost savings, while not sought explicitly, would of course be very welcome.

Automation and the role of Visual Components

Invio Automation started the process by reviewing the customer’s current practices during an on-site workshop at the factory. The Factory of the Future team worked with the client to identify 14 potential automation and process improvement opportunities. In the subsequent investigations and discussions, the collection of 14 projects was narrowed down to three concepts that had a high probability of increasing throughput.

Each concept was investigated carefully, exploring options, identifying the types of equipment to use in window manufacturing, and the expected benefits. Invio used Visual Components software to help them with these activities.

A leader in 3D manufacturing simulation, Visual Components monitors trends in automation and robotics to better provide manufacturers with tools for exploring production line concepts, cells, and workflows. While often used for manufacturing process optimization, it’s also a tool for evaluating the output to be expected from new production equipment, layouts, and workflows. It permits the assessment of factors like robot reach and cycle time, identification of production constraints, and evaluation of potential throughput rates, given varying production schedules.

A particularly important aspect of Visual Components software for integrators like Invio Automation is the ability to produce a 3D concept rendering of a proposed arrangement or layout. This helps a team developing automation concepts explain their ideas, and so get better quality feedback and direction from the client.

In their “Factory of the Future Consulting” study, Invio used Visual Components software to create automated work cells, conceptualize automation solutions, and present these to their client.

Benefits of Visual Components in identifying potential automation cases

At the time this consulting study began, Invio Automation was new to Visual Components factory simulation software. Previously, the Invio team relied on a combination of 3D CAD and PowerPoint to communicate ideas and iterate with their clients. For this study, however, Invio’s engineering team to see what could be gained from using Visual Components simulation software.

The team saw benefits in three areas:

1. Speed
2. Customer communication
3. Quality of concepts developed

In terms of speed, the Invio team estimates that by using Visual Components software, their workflows were sped up three times compared to how iterations were previously done. They also observed a noticeable improvement in customer perception and understanding of the concepts presented.

As to the quality of the concepts, the team felt Visual Components software was well suited to different levels of automation. Said Ben Graham of Invio Automation,

“It was so flexible… Whether we were in the concept of this fully automated cell, [or] looking at some material flow for a semi-automated cell, we found the tool very powerful and valuable as we tried to determine what was best for the customer. The flexibility of the tool was tremendous and enabled our team to explore various levels of automation”

Simulating automation in window manufacturing

Invio’s consulting process concludes with a formal report presented to the client. The report Invio Automation produced for the window manufacturer addressed:

• Potential automation projects
• High-level estimates of costs and benefits
• Hardware/equipment requirements

Invio found that supporting these somewhat “dry” facts and figures with 3D concept renderings and even animations of the proposals added a lot of weight to the proposals. Ben Graham of the “Factory of the Future Consulting” team said,

“We switched over to Visual Components and showed the Visual Components model after the PowerPoint, and they really seemed to grasp it and understand it [the possibilities for automation and the scope of the project].”

Using simulation to “sell” ideas

The Invio team was excited by how their client responded to the use of Visual Components software.

“We 100% saw a noticeable increase in positive feedback from the customer when we showed our results using Visual Components.”

Ben Graham, Senior Consultant, Factory of the Future Services at Invio Automation

This illustrates that factory simulation is more than a tool for manufacturing process optimization. It is a way to explore options to communicate and discuss ideas more effectively. For integrators like Invio Automation, simulation is an essential tool for business development and satisfying customers. The importance Invio places on simulation is evident, as they are committed to incorporating it into their future projects.

Visual Components

Founded in 1999, Visual Components is one of the pioneers of 3D simulation. Visual Components’ 3D simulation helps industrial production companies design, test, optimize, and develop production lines as efficiently as possible. Visual Components’ Robotics OLP software, along with 3D simulation, form a software solution for digitalizing production systems that significantly reduces downtime, saves production time, and improves robotic programming processes.

Want to learn more about the benefits of our solutions for your business? Contact us today!

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This case is about an international technology competition held in China where over 7000 students participated in enhancing their skills in modern industry technologies for robotics, automation, and digital twin using Visual Components-based simulation solution. The ease of use and wide industrial application of the Visual Components solution gave MeiCloud an advantage over other simulation software to be chosen as the only solution provider for this competition. The students participating received active training and technical support from MeiCloud’s team throughout the competition.

15th International Advanced Robot and Simulation Technology Competition

The International Advanced Robot and Simulation Technology Competition is the first and only high-end discipline competition initiated by Chinese universities. Students from all over the world including countries such as the United States, the United Kingdom, Germany, the Netherlands, Australia, Norway, South Korea, etc. participate in this event together with their Chinese counterparts.

The main goal of this kind of competition is to promote simulation technology in colleges and universities, attract more talent to simulation and increase the skills of students by using manufacturing simulation tools together with theoretical knowledge. With the use of simulation, the students start to understand the real-life challenges of industries and learn to solve them by designing the smart factories of the future.

This was the 15th series of this competition which was held from the 1^st to the 30^th of November 2022. In total, 1510 teams participated in this competition from 369 schools. Each Team on average comprised 5-6 students. In the Online Competition, 190 teams won the first prize, 275 teams won the second prize and 320 teams ended up winning the third prize depending on the level of simulation, production knowledge, and execution of the designs.

Over the years, the competition has become an important stage for students from around the world to show their skills in robot research and development, production, and application, and build a bridge for mutual learning and knowledge exchange.

Project description

The layout below is from one of the winning teams of the competition coming from the North China Institute of Science and Technology. This team designed a smart factory that manufactures impellers, which are typically used in pumps for turbomachines.

The students used simulation technology to create a working model of a smart factory that could be used by other universities. These are the systems that are connected to the simulation model at the core of this project,

1. They used the existing university laboratory and factory of the school and built a connection with the MES (Manufacturing Execution System).

2. They Used 5G technology to collect operational data and monitor the production process of the factory.

3. Additionally, they had a central control system that displayed real-time pictures of the entire production line with workpieces flowing through each station together with real-time machine data.

The simulation model of the plant consists of three parts.

• Processing Area
• Practice Area
• Explanation Learning Area

This full-fledged smart factory project mainly used these features of Visual Components,

• Process flow simulation
• Signal connectivity module
• Robot teaching/programming
• Statistical analysis

Factory layout simulation flow

This was the material and process flow of the impeller smart factory,

–  Two parts per box pulled from the warehouse for the machining process (milling, lathe, etc) and in parallel the conveyor on the side has two parts per box that come from the warehouse that includes a fixture, base, and a clamp nut to mount the in-process impeller on it before its ready. The CAD geometries of the impeller, fixture, base, and clamp were designed in SolidWorks and were imported into the simulation model.

After another Worldwide recognition of the event, MeiCloud will continue these kinds of competitions in the future, perhaps also in other regions of the World. The competition shows the advantages of using Visual Components technology in an education setup, allowing the students to quickly master powerful simulation technology to create digital twins, practice virtual commissioning, and prepare them for the challenges they will experience once they graduate.

If your company wishes to organize similar events and needs support from Visual Components, get in touch with us today!

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The role of manufacturing in shaping the future

Awareness of the latest developments in manufacturing is essential for anyone interested in the future of the economy, society, and the world. The Danish Technological Institute (DTI) is well aware of the importance of keeping up with the latest developments. They provide technology-based services to companies and public organizations in Denmark. Their mission is to help Danish companies and organizations stay competitive in the global market by providing them with access to the latest technologies and knowledge. Their use of Visual Components is a prime example of this, as it has allowed DTI to create virtual layouts of their clients’ manufacturing facilities, helping them visualize the potential for automation, for example, and helping identify and resolve issues before they occur.

DTI’s research and innovation services are tailored to the specific needs of each client project. DTI is not supplying turnkey solutions but is more active in helping companies make their next step. DTI’s Senior Specialist, Martin Mølbach Olsen, recently worked on a project with a large manufacturer of box-packaging machinery for food products who were looking for ways to automate their manual palletizing process. The company had been manually palletizing boxes with packaging materials, but as their production volume increased, they were looking for ways to automate this process to keep up with demand.

DTI used Visual Components to create a virtual layout of the company’s facility and show them how robots and other key equipment could automate the palettizing process. This allowed the company to visualize how the manufacturing layout would work in their specific environment and understand the benefits of automation as a means not only to help streamline their processes but also to provide material to help convince decision-makers within the company of the possibilities available.

“Visual Components helps our customers to visualize how an automation project could look and thereby help them make the right decisions.”

– Martin Mølbach Olsen, Senior Specialist, PhD Food and Production, DTI.

Visual Component’s eCatalog and VR features providing clarity

With simulation, in general, it’s easier to move the robot on the shop floor rather than make adjustments in real life. A 3D model gives perspective and helps the manufacturer make an informed decision. Buying the first robot or piece of equipment can be daunting, so Visual Components allows for greater understanding and helps the customer go ahead with a project. With DTI’s experience working with various customers across different industries, they often find that their clients can be unfamiliar with robots or mobile robots and how they can be used in their manufacturing processes. With Visual Components’ eCatalog, DTI could integrate robots and other key equipment into their existing systems and processes.

“Visual Components is a very comprehensive tool that comes with a lot of ready-to-use components, making the process of building a 3D simulation quite quick and easy. At the same time, it is also wonderful that it is possible to customize almost everything, giving the possibility to build customized components.”

– Martin Mølbach Olsen, Senior Specialist, PhD Production and Innovation, DTI

They also use the VR feature of Visual Components Experience for visualization and communication in virtual walkthroughs of the factory floor.

DTI’s role in helping Danish companies stay competitive in the global market

Using Visual Components has allowed DTI to provide their clients with a better understanding of how robots and other key pieces of equipment can be integrated into their existing systems and processes.

DTI will keep using Visual Components as a critical tool to assist Danish companies and organizations in staying competitive in the global market.

If you want to learn more about Visual Components and wish to choose the right tools and the best way forward with our software, please get in touch with us here.

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Flexibility is key in small-batch production

HT Laser’s customers are mainly Finnish machine manufacturers, for whom it supplies various products as a subcontractor. Production is mainly in small batches, and the products are always tailor-made to the customer’s needs. In terms of productivity and profitability, this requires a lot of flexibility in production, systematic production planning, and the right systems, equipment, and software.

“The most important thing in subcontracting business is to be able to adjust production to the customer’s needs. Sometimes you have to be able to respond quickly when demand is high, and on the other hand, be able to reduce capacity when demand slows down. Flexibility is the key in this business. Offline programming of robots and Delfoi software (now known as Visual Components Robotics OLP) plays a key role in this,” says Janne Tuominen, Product Development Manager at HT Laser Oy.

Robotization is at the core of development

HT Laser has been using welding robots in production for about twenty years and they are used for welding various products. HT Laser and its subsidiaries use robots from several different manufacturers, such as KUKA, OTC, ABB and Yaskawa. The use of these robots is expected to increase in the future.

“We use robots for welding whenever good accessibility is possible, when the number of welding hours is high, or when the number of pieces to be welded is so large that a person can no longer do it. The benefits of using robots are that they can weld tirelessly and the desired quality is repeatable,” says Janne Tuominen, Product Development Manager at HT Laser Oy, and continues:

“Our goal has always been to increase the automation level of production, and Delfoi Robotics plays a key role in offline programming of robots.”

Offline programming of robots brings many benefits

Offline programming is a production-uninterrupted method of programming robots, where the program for the robot is created on a computer outside of production. Delfoi Robotics’ product family covers software for numerous applications in almost all industrial robot applications and is compatible with all robots, regardless of brand. The Delfoi ARC software effectively utilizes the features of a 3D CAD model of a welded piece and welding information, making the generation of programs fast and error-free.

“The benefits of offline programming are realized in our production every day. The biggest benefit is time-saving as programming can be done without stopping production and expensive machines. Timesaving is also achieved by certain software macros that speed up the programming process. Offline programming also solves the problem if the welded piece is large or located in a place where it is difficult or unsafe to climb”, says Janne Tuominen, and continues:

“Offline programming is also location-independent, and we can program robots from one location to several of our factories. That is why we are investing in offline programming expertise and specialization in cooperation with Delfoi Robotics.”

Investment in automation and offline programming together

Investment in production automation and robotics requires ongoing development work. HT Laser is participating in the national AITOOLS1 development project, which aims to measure and verify the benefits of robotics through research. In the three-year project, machine learning models will be developed that are capable of dynamically adjusting and optimizing the robotic welding process. Delfoi Robotics is also participating in the joint project with VTT, Tampere University, and various companies.

“Our strategy is to continuously increase the level of automation. With regard to robotics and offline programming, I would say that we will strongly invest in and grow this aspect. It is good that we have a knowledgeable partner like Delfoi Robotics, with whom we build this future,” sums up HT Laser Oy’s product development manager, Janne Tuominen.

About Visual Components

Founded in 1999, Visual Components is one of the pioneers of 3D simulation. Visual Components’ 3D simulation helps industrial production companies design, test, optimize, and develop production lines as efficiently as possible. Visual Components Robotics OLP software, along with 3D simulation, form a software solution for digitalizing production systems that significantly reduces downtime, saves production time, and improves robotic programming processes.

Want to learn more about the benefits of offline programming for your business? Contact us today!

The post Offline programming for increased speed, quality, and productivity in the metal industry appeared first on Visual Components.

Etteplan is a leading technology service company from Finland that specializes in engineering solutions and helps industries optimize their processes through effective digitalization. Their business is divided into three key areas, engineering solutions, embedded software, and technical documentation services. This case study mainly covers the engineering services and is drawn from a conversation with the Business Unit Director, Iirotapio Aalto, and Automation Team Manager, Juha Lantta at Etteplan. 

How Etteplan Integrates 3D Simulation into Their Operations

Etteplan’s customer projects mainly include industrial equipment design and engineering. Their use of Visual Components software begins very early in the project process, where they use it to create and share layout concepts with their customers. This facilitates discussions that help Etteplan and their customers hone ideas and expectations and agree on an approach about the direction to take for the projects. It helps build stakeholder buy-in before moving forward with detailed engineering work. 

Iirotapio Aalto, Business Unit Director: “We see the two-way benefit of Visual Components, first is convincing the customer that they are investing into the right solution, at the same time the benefit for us is to verify early on what we are capable of delivering.”

Etteplan also uses 3D simulation for virtual commissioning. It lets them work out details of the controls strategy before equipment is built, which is when it’s easier and cheaper to make changes. It saves time later in the project because work done building the model early on can be reused in subsequent phases of work. 

Juha Lantta, Team Manager, Automation: “The main benefit is we have an open discussion through the visual model with the customer … so we are talking about the same things at the same time. It’s easier to show what we are trying to solve through the [Visual Components] models.”

Before and After Using Visual Components Software 

Etteplan’s business involves communicating ideas and concepts to customers, and explaining how the new cell or equipment will work. Before adopting 3D simulation, this work was done with static CAD models. At the time those were the accepted methods but of course, they did not provide enough insights into the systems for effective planning and decision-making.

Today Visual Components software has changed both customer expectations and the actual workflow of the business processes. Customers appreciate how 3D simulation can show them what they are buying, and also how it facilitates discussions about how equipment should work. As a result, it’s now something they expect to see used in the project design phases.

Simulation has also changed how projects are planned and executed within Etteplan. Visual Components software is now embedded throughout the process, from conception in the sales stages to detail design, virtual commissioning, and implementation. This saves time, reduces the risks inherent in later project stages, and enables a faster ramp-up. Etteplan thinks in the future the software will be used to assess the risks and feasibility of upgrading systems previously developed and installed with the help of Visual Components.

Once we show [our customers] virtual models and concepts the expectation is more and more. In every case, I would say… our customers are expecting it.

Iirotapio Aalto, BU Director Etteplan

Looking Towards the Future

Based on their experience to date, Etteplan is sure their use of Visual Components software will continue to grow. Customers expect it and it benefits the way projects are conceived, sold, and executed. 

Etteplan notes that automation tools and standards keep evolving and improving: their request is that Visual Components continues to keep pace, updating to incorporate changes in communications protocols and plugins for PLC and robot connectivity. They’re also looking forward to developing digital twins where they can import real-world data into the Visual Components model for improved process optimization. And last, they expect to see Visual Components growing as a tool for predicting and planning management of system failures such as component or machine breakdowns.

Iirotapio Aalto: “Visual Components will be used more often in our future automation projects. It can be used for R&D projects as well. Any kind of automation [or] mechanical interaction, can be simulated using Visual Components” 

Learning From Users

Testimonials are a powerful way of learning about the benefits and capabilities of a product or service. In this case, study leaders at Etteplan have shared their experience with 3D manufacturing simulation from Visual Components and explained how it is helping them grow their business. If you’d like to learn more, contact us today.

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