Automated into the future
MERZ tronic GmbH, based in Villingen-Schwenningen, has its origins in the development of printed circuit boards and the assembly of industrial cathode ray tube monitors. Founded in 1998, the company has expanded its range of services over the years to include mechanical production and now has 18 employees. MERZ tronic supplies companies in almost all industries with customized monitors and data input systems. The family-owned company now relies on six machine tools from DMG MORI for its machining. Following its first purchase in 2018, a DMU 95 monoBLOCK, MERZ tronic has been pushing ahead with automated production for around three years now. A CMX 70 U with PH 150 was the first step. This was followed by a CTX 450 TC, a DMU 50, and another CMX 70 U – all with Robo2Go robotic automation. In the case of the CMX 70 U, the automation was a retrofit that allowed the 5-axis milling machine to be better utilized.
Touchscreen displays for the medical industry
The now almost universal use of touchscreen displays as data input systems has given MERZ tronic access to numerous industries in recent years. “Intercom systems, machine controls, and monitors for medical use are just a few examples,” says Florian Merz, who runs the company together with his father. “We support our customers right from the development phase and supply ready-to-install systems from a single source.” MERZ tronic stands for a high degree of flexibility and individual customer service.
Productive 5-axis machining of complex workpieces
Modern manufacturing plays a major role in MERZ tronic's flexibility. “Above all, our investments in machine tool technology from DMG MORI have brought us a long way,” recalls Florian Merz. The large working volume of the DMU 95 monoBLOCK had already been fully utilized to manufacture demanding 5-axis components. This positive experience led to further purchases. “5-axis machining is essential for our range of parts because it allows us to competitively manufacture even complex workpieces in a maximum of two clampings,” adds Michael Schmid, Production Manager.
PH 150: Entry into automated production
In a further investment phase, MERZ tronic focused on automation solutions. According to Florian Merz, there were two main reasons for this: “Order intake rose dramatically after the COVID-19 pandemic, so we had to increase our capacity. However, this was hampered by the challenge of finding skilled people to work additional shifts when necessary.” The PH 150 pallet handling system on the CMX 70 U showed how such a problem could quickly be solved. “It allowed us to continue working in two staggered shifts during the day and have additional workpieces processed overnight,” said Michael Schmid.
Robo2Go: Greater flexibility through robot-based workpiece handling
After his initial experiences with the automated CMX 70 U, Florian Merz was quickly convinced. “The PH 150 pallet handling system is an enormous benefit, especially for workpieces requiring longer running times, because it allows our employees to focus more on, for example, programming during the day.” The purchase of additional automation solutions was therefore a logical consequence. “In Robo2Go, we have found a workpiece handling system that offers us even more flexibility in autonomous production.”
Minimally-attended production of 80 components at a time
The investments in a DMU 50 and a CTX 450 TC quickly paid off. With the help of Robo2Go, both machines can produce medium batch sizes over several hours without manual intervention. The turning and milling center also has a bar feeder, which offers additional flexibility in order planning. “Depending on the workpiece size and magazine capacity, we can produce up to around 80 components at a time,” explains Michael Schmid. This allows MERZ tronic to make even better use of unattended late and night shifts. “If necessary, one of us fills the magazine at weekends.”
Increased capacity thanks to Robo2Go retrofit
MERZ tronic also wanted to benefit from the flexibility of Robo2Go in the case of a CMX 70 U that had not yet been automated. “That's why we commissioned DMG MORI to retrofit the robot,” recalls Florian Merz. The side door was already in place as preparation for automation. However, the system was designed for pallet handling. To be able to use a workpiece handling system, it had to be retrofitted by a technician from the DMG MORI plant in Poland where the machine is built. “The entire retrofit took only four weeks. After that, we were able to get started right away because we were already familiar with the Robo2Go.”
Easy robot programming without prior knowledge
Michael Schmid sees the ease of use of the Robo2Go as another advantage of the workpiece handling system: “After receiving training from DMG MORI, I was able to program the robot very quickly, without any prior knowledge.” All you have to do is enter parameters such as the size of the raw material and the exact position in the magazine. “Data input is very intuitive via the multi-touch display of the machine control system.”
Automated future
Florian Merz is pleased about the move to automated production: “We can respond to economic fluctuations much more confidently, while at the same time deploying our skilled staff more effectively on qualified tasks.” He intends to continue to consider this subject in future investments. “We will incorporate automation solutions into our strategy in order to remain competitive over the long term.”
MERZ tronic GmbH
Siederstraße 50
78054 Villingen-Schwenningen
Merz tronic