SmartFlow System with storage stacker crane

NETECS Spółka z o.o., specializes in the design and manufacture of centrifugal fans that are used in dust collection systems for many industries, including hazardous areas. It supplies low-, medium- and high-pressure fans for pumping clean or dusty air. In view of the highly variable market environment and the need to constantly improve the efficiency of production processes, the company’s management decided to implement automation in the area of sheet metal processing.

Increasing the profitability of the cutting process

Prior to the implementation of automation, sheet metal was stored on stationary racks and was transported to the machining machines using forklifts. Due to the number of machines involved in the machining process, the organization of material delivery was complicated and time-consuming. Previously, the loading of raw material was carried out using cranes, while the collection of cut parts was done manually. This way of processing orders proved costly and negatively affected production margins.

Reducing the role of forklifts in the material handling process

The number of machines used in production necessitated the involvement of multiple operators to operate forklifts. Achieving an adequate level of productivity required working three shifts and often on weekends as well. The lack of automation meant that plan execution depended on the availability of employees and their effective and efficient work.

Optimizing the execution of High-Mix Low-Volume orders

In a High-Mix Low-Volume production model, where assortment changes and short runs are a daily occurrence, the ability to adapt quickly and be flexible is key. Performing multiple operations manually in such an environment is very difficult and limits the ability to execute orders efficiently.

A line for automatic sheet metal cutting using two TRUMPF laser cutters – one with automatic loading of raw material and unloading of cut details, the other operated for delivery of raw material near the laser work table.

The line consists of a MultiTower automatic warehouse with a stacker with a capacity of nearly 750 tons of sheet metal, a system for transporting individual sheets to the cutting machine, a system for transporting cut-out parts from the cutting machine, and the BAUMALOG Planner Lite information system. All components of the system are mechanically, signal and IT integrated.

The CAD/CAM software, TruTops, is responsible for the technological part of the process, including the creation of nesting, while the Planner Lite software provided by BAUMALOG allows efficient planning and management of the order queue.

Taking care of the optimal flow of material, three press brakes have been located directly next to the automatic warehouse, which in the bending process use raw material or previously cut parts, which after processing on the laser cutter returned to the BAUMALOG system.

• Increase production efficiency and increase production profitability.
• Reducing to a minimum the importance of forklifts in the sheet metal cutting area.
• Readiness to efficiently execute short-run and unit orders (High-Mix Low-Volume).
• Reduction of the number of operators involved in the sheet metal cutting process.