Standardized setup processes increase productivity and lay the foundation for flexible, automated single-part production. Real-world examples demonstrate how to successfully get started.
Increasing demands on quality, delivery times, and cost-effectiveness pose major challenges, particularly for contract manufacturers. At the same time, small batch sizes, complex components, and individual customer requirements make consistent standardization difficult. The event “From Standardized Setup Processes to Automated Single-Part Production,” organized by ProduktionNRW, demonstrated how companies can successfully resolve this conflict of objectives while simultaneously laying the groundwork for automated production. The event was hosted by Berghoff GmbH in Drolshagen.
Following the welcome and company presentation by Ullrich Berghoff, the focus initially turned to the topic of setup at Berghoff. Andy Schmidt-Wohlrab explained the company’s initial situation: Complex components, small batch sizes, and high demands on quality and precision led to numerous clamping changes and custom solutions, despite the company’s existing zero-point clamping systems. For some components, up to 22 clamping operations were required, resulting in significant setup effort and corresponding costs.
He then presented the decision-making process leading to the introduction of a new clamping concept. The goal was to reduce the large number of custom fixtures, continue using the existing grid plates, and at the same time maintain the necessary flexibility for single-part production. The decisive factor for implementation was the ability to combine standardization, low-stress clamping, and easy integration into CAM processes.
In the second part of the presentation, Andy Schmidt-Wohlrab and Igor Kudraschow from FCS System S.r.l. presented the implementation and the initial results. Using a pilot project as an example, they demonstrated how standardized clamping systems enabled a significantly more efficient setup process. Building on the successful pilot project, Berghoff gradually developed a systematic approach to further standardize applications and reduce one-time costs.
During the subsequent plant tour, participants had the opportunity to see the presented solutions firsthand on the production floor and discuss practical experiences with those responsible.
In the afternoon, Ricardo Vieweg from Tebis Consulting demonstrated how the standardization of tools, clamping devices, and processes lays the foundation for further automation. It became clear that automation does not begin with robots, but rather with stable and well-controlled processes. In the subsequent workshop, participants discussed their own challenges and exchanged experiences regarding standardization, digitization, and automation in single-part manufacturing.
As a result, the event evolved into a practical exchange of experiences on how companies can increase their productivity through standardized setup processes while simultaneously laying the groundwork for automated manufacturing. The examples presented made it clear that the path to automation begins with clear standards and end-to-end processes.
The organizers and participants would like to thank Berghoff GmbH for its hospitality and the speakers for their candid insights into real-world practices, and they look forward to future events within the ProduktionNRW network.
Organizer
The event was organized by ProduktionNRW. ProduktionNRW is the cluster for mechanical engineering and production technology in North Rhine-Westphalia and is managed by VDMA NRW. ProduktionNRW serves as a platform to connect, inform, and promote companies, institutions, and networks with one another and along the value chain. Significant portions of the services provided by ProduktionNRW are funded by the Ministry of Economic Affairs, Industry, Climate Protection, and Energy of the State of North Rhine-Westphalia.