Growing demands for quality, delivery reliability and repeatability mean that modern CNC machining increasingly goes beyond the operation of the machining center itself. The key is to automate the entire production process – from workpiece preparation and loading, through machining, to pallet changes and the start of the next job.
Well-designed CNC automation primarily enables better utilization of available machine time, reduces downtime and improves process stability.
Why is CNC automation becoming increasingly important?
In a traditional production model, the operator prepares the workpiece, clamps it in the machine, starts the process and, once machining is complete, replaces the workpiece or tooling. As a result, even a highly efficient CNC machining center may remain idle for part of the available production time.
Production automation helps reduce these interruptions.
Automated pallet handling systems allow subsequent jobs to be prepared outside the machine’s working area. While the machining center is processing the current job, the next workpieces can already be prepared for production.
In practice, this can provide:
- higher utilization of machining centers,
- shorter intervals between operations,
- more efficient multi-shift production,
- improved process repeatability,
- more effective use of operators’ working time,
- the ability to handle more orders with the available production resources.
Automation is not only for high-volume production
Automation is often associated with manufacturing thousands of identical parts. In modern CNC machining, however, its application is much broader.
Pallet systems and flexible manufacturing solutions can also be particularly useful for small and medium production batches and a diversified range of components.
Different fixtures and different workpieces can be prepared on individual pallets. Once one job has been completed, the system can automatically prepare the machine for the next one.
Automation therefore does not have to mean producing large quantities of identical components. It can also provide flexible management of multiple, different production orders.
Pallet systems – more time for actual machining
Pallet storage and automatic pallet changing systems are important elements of modern CNC automation.
Their purpose is to deliver a prepared pallet to the machine’s working area without requiring manual operator intervention each time.
This makes it possible to separate:
machine operating time from preparation time for the next job.
The operator can prepare the next setup while the CNC machining center is already performing another operation. Reducing machine waiting time directly increases its actual utilization.
5-Axis Machining and Automation
Combining automation with 5-axis CNC machining centers offers particularly significant potential.
5-axis machining makes it possible to machine multiple surfaces and geometrical features of a component in a single setup. Reducing the number of setups can shorten the production process and minimize the risk of errors associated with repeated workpiece positioning.
The combination of:
5-axis machining + pallet systems + appropriate tool management
makes it possible to create flexible production cells capable of processing subsequent jobs with limited operator intervention.
HERMLE HS flex heavy – an Example of Flexible Automation
One example of this approach is the HERMLE HS flex heavy automation solution used in combination with HERMLE machining centers.
The automated pallet handling system enables multiple production jobs to be prepared and processed sequentially. This helps increase the proportion of actual cutting time within the total available operating time of the machining center.
For a manufacturing company, however, the speed of an individual machining operation is not the only important factor.
What increasingly matters is overall process efficiency – from production preparation to completion of the entire order.
Production with Reduced Operator Attendance
One of the objectives of automation is to extend the effective operating time of machines.
A properly prepared process can enable production to continue during periods of reduced operator attendance. This requires stable machining technology, appropriate tool preparation, tool wear monitoring and suitable
Therefore, unattended production is not simply about adding an automated pallet storage system.
It requires the effective integration of multiple elements:
machines, automation systems, cutting tools, fixtures, manufacturing technology, and production management systems.
Automation, Quality and Repeatability
The benefits of automation extend beyond the number of parts produced.
Reducing manual operations can also improve the repeatability of the manufacturing process. This is particularly important in precision machining of components with tight tolerances.
Standardized fixturing, automated pallet handling, and reducing the number of repeated setups help maintain stable production conditions for subsequent workpieces.
Automation should therefore be considered not only as a way to increase productivity, but also as an important element in creating a stable and predictable manufacturing process.
CNC Production Automation at Sacher
At Sacher, we are continuously developing our machine park towards higher levels of automation and greater capabilities for technologically demanding projects.
The combination of modern machining centers, 5-axis machining, automation systems, and quality control enables us to expand our production capabilities and plan the execution of subsequent orders more efficiently.
Investments in solutions such as the HERMLE C 400 with the HS flex heavy system are part of this development strategy.
Our goal is not automation for its own sake. Our objective is to create a manufacturing process that provides our customers with high quality, repeatability, flexibility, and predictable production performance.