The Fehlmann Versa 945, combined with a customized automation solution from Gibas, forms the mechanical core of Escha’s new manufacturing platform. © Escha GmbH & Co. KG

The production organization also no longer met the requirements. “Tool management and production planning were largely based on manual processes. We had a veritable sea of Excel spreadsheets,” recalls Benjamin Unruh, project manager at ESCHA. “Tool variances were calculated once a day, and if anything came in after that, the order just had to wait.”

Digitalization as a Starting Point

Instead of simply replacing a milling machine, Escha first developed a digitalization strategy for toolmaking. At the end of 2021, the company implemented a manufacturing execution system (MES) and control system with tool and job management. At the same time, a set of specifications was developed that defined all requirements for the machine, automation, and digital integration.

At the heart of the automation system is a robotic cell equipped with a Fanuc robot that can easily handle components of various sizes—from small electrodes to large mold plates. © Escha GmbH & Co. KG

“The robot is equipped with a specialized barcode scanner and a laser sensor for presence detection. This system serves as a critical safety feature. Before each transfer to the Versa 945, the robot scans the pallet at the transfer station and verifies its identity and correct orientation,” explains Enrico Akkerman, CCO at Gibas.

The system is supplemented by a washing station that cleans tool components at ambient temperature and automatically selects the appropriate cleaning program via the MES and control system.

Digital Process Control

The "Evomecs" MES and control system handles order control, tool management, and machine scheduling. Tools are identified using 2D codes and monitored based on their service life.

“To prevent tool breakage, we used to play it safe and change tools early. Today, we make decisions based on real machine data. We know at all times which tool has been in use, how long it has been running, and how much remaining life it has. This gives us significantly more reliability and transparency throughout the entire manufacturing process,” explains Benjamin Unruh.

According to the company, productive machine uptime rose from an average of 8.75 to about 15 hours per day.

“That represents an increase of over 70 percent,” says Benjamin Unruh happily. “And the operating times are much more stable and predictable now.”

At the same time, tool breakages and scrap decreased. On-time delivery rates increased from about 55 to 88 percent.

“The processes are much more transparent and easier to plan today,” says Unruh. “This allows us to respond more flexibly to last-minute changes. And that’s how we’ve also started taking on projects from external clients.”

The rollout of the manufacturing platform was accompanied by a multi-stage training program.

“We wanted to fully involve the employees,” emphasizes Benjamin Unruh. “In my view, the high level of acceptance of the new systems is a key factor in the project’s success. After all, it is the combination of modern technology and qualified employees that enables the stable and largely autonomous production we sought to achieve with this project.”