Dual automation for two TRUMPF cutting machines

Marbo Sport is a Polish manufacturer of high-quality sports equipment and gym equipment, which has been consistently developing its offer for over 30 years and gaining the recognition of customers in Poland and abroad. In the production plants located in Starachowice, the company implements technologically advanced projects, combining modern design, durability and functionality of its products. Dynamic development and a constantly growing number of orders prompted Marbo Sport to optimize logistics and production processes, which resulted in the implementation of an automation system, ensuring further increase in the efficiency and flexibility of orders.

• Increased production efficiency – Difficult material flow and time-consuming access to a diverse range of products effectively limited the full use of the production capacity of laser cutting machines. Despite well-optimized processes, Marbo Sport reached a point where it became impossible to increase production further without the purchase of more cutting machines or the introduction of automation.

• Layout of the production hall and material flow – The expansion of the machine park, necessary due to the dynamic development and foreign expansion of the company, encountered limitations resulting from the narrow layout of the production hall. For this reason, it was not possible to implement typical automation systems for loading and unloading laser cutting machines, due to the lack of available space.

The client’s hall and the arrangement of the other production machines required an unconventional approach and idea. The final project assumed the implementation of an automated TwinTower storage system with a capacity of 66 tons of metal sheets, cooperating with two automation modules:

• Loader 3015 – moving along the long side of the laser cutting table.
• MultiLoader – operating the laser table from the short side.

This solution made it possible to place two TRUMPF laser cutters opposite each other with the faces of the work tables, which significantly optimized the available space in the production hall and increased the efficiency of the lasers without the need to expand the hall.

The process of planning and managing sheet metal cutting has been entrusted to our proprietary Smart WMS Production software, which works in full integration with the ERP system and the CAD/CAM TruTops program – which ensures data consistency, task automation and greater control over production.

• Full automation of two laser cutters occupying less than 120 m².
• Shortening the access time to each assortment of sheets to 3 minutes.
• The ability to load laser tables every 1.5 minutes (40 cycles per hour).
• Automation of the cutting process enabling night and weekend work – without the constant presence of operators.