In partnership with KUKA, KRONE accelerates intelligent automation across brownfield and greenfield sites: at Werlte (brownfield), handling and welding cells coordinate with autonomous mobile robots (AMRs) to streamline production; at Ibbenbüren (greenfield), the GTS smart factory integrates KUKA robotic cells and AMRs for flexible material flow and high-efficiency welding.
In truck trailer production in Werlte, six-axis KUKA handling and welding robots work together in a digital network with AMRs such as the KMP 1500P. Previous processes were first put to the test and then converted to new working methods such as modular construction.
The welding robots are supplied autonomously, and forklifts are to be eliminated from production as far as possible. Instead, the transport platform automatically brings materials such as compressed air tanks or door elements to the cell. There, a handling robot places them in the welding system. The finished assemblies are also transported away automatically from there. This significantly increases efficiency in production and intralogistics processes and relieves employees of heavy, monotonous tasks.
Volker Perk, Production Director at KRONE Commercial Vehicle Group, sees robotics as a key factor in securing the company’s future location: “We want to continue producing truck trailers such as the ‘Profi Liner’ in Germany in the future. To do this, however, we need to automate processes because we simply cannot find skilled workers for many of the tasks required. Robotics gives us the opportunity to introduce our employees to more efficient or value-adding activities.”
Connected and digital: the Ibbenbüren smart factory
While Werlte continuously modernizes existing processes, a completely new factory for agricultural machinery production was built in Ibbenbüren, Westphalia, in just twelve months, literally on a greenfield site. With the support of KUKA, KRONE relied on state-of-the-art, smart, and sustainable manufacturing concepts and processes.
Every machine, every robot, and every transport vehicle in the Smart Factory is digitally connected. This allows production to react immediately to any tolerance violations or malfunctions. The systems are adaptable; they learn and correct themselves independently. In a single production cell, nine welding and handling robots work synchronously with two machining centers and an automatic measuring cell. This has virtually eliminated downtime and allows production to be ramped up or scaled back flexibly. The first heavy-duty AMRs, such as the KMP 3000P, are also being tested in Ibbenbüren. It can move up to three tons in the production halls, twice as much in tandem, and move omnidirectionally with the highest precision even in the tightest of spaces.
“We make work more attractive”
One thing is particularly important to KRONE’s factory planners: automation does not mean the end of human work, but rather its enhancement. Internal colleagues would actively apply for these positions. Ergonomics also plays a role: “The new workplaces are safer and less physically demanding. That makes them attractive – especially for younger generations,” says Perk.
