Automation and Efficiency working with the Integrated Working Cell

Haller Industriebau GmbH, is a German company based in Villingen-Schwenningen, located in southern Germany, strategically positioned between Stuttgart and Zurich. Specializing in steel construction and lightweight metal construction, Haller Industriebau is equipped with cutting-edge technology that enables high-precision work across various materials.

Recently, the company expanded its operations by increasing their composite aluminum manufacturing department, further enhancing overall quality too in a competitive industrial market.

In response to the growing demands of the market, we focused on optimizing Haller Industriebau’s production process. The company faced several key challenges: increasing production efficiency, addressing labor shortages, and ensuring continuity after the retirement of a long-standing employee who had been responsible for both programming and operating their machinery. With these factors in mind, Haller Industriebau aimed to streamline operations while maintaining or increasing output with fewer staff members.

To tackle these issues, we provided a solution tailored to our customer own work process by implementing an integrated working cell: the Ranger CNC Panel Router with Vertical Table, featuring an advanced automatic loading – Double Loader machine – and unloading system (our Off Loader). This innovation allowed the company to handle materials more quickly and efficiently, with the flexibility to choose which side of the panel to process, independently on how it was stacked up. Moreover, the integrated software simplified machine programming, enabling rapid adjustments and easier operation for the remaining staff.

As a result, Haller Industriebau was able to maintain optimal production levels with a reduced workforce, achieving their goal of increased efficiency. Our approach included key customizations specifically designed to meet Haller Industriebau’s needs.

The Integrated Working Cell not only improved operational flexibility but also provided a backup system in case of machine failure of the existing Ranger Cell, enhancing the overall reliability of the production process. This customization played a pivotal role in ensuring smooth, continuous operations.

Haller Industriebau experienced tangible benefits from the solution, including the ability to maintain or exceed previous output levels with fewer employees. Following the retirement of a senior operator, the company successfully managed to continue operations with one remaining employee overseeing tasks that had previously required two. This improved efficiency highlights the success of the solution. In addition to the requested improvements, we delivered several unexpected advantages.

The enhanced software and flexible loading system reduced the time required for training new or existing staff, streamlining the overall production workflow. The backup capabilities provided peace of mind, ensuring that production could continue uninterrupted, even in the event of a technical issue.

Haller Industriebau expressed great satisfaction with the collaborative process. They appreciated not only the technical improvements but also the outstanding customer support provided during the implementation. They noted that our service surpassed their expectations, ensuring a smooth transition and successful integration of the new system.

This project taught us the importance of customizing solutions to address the specific challenges faced by each client. In Haller Industriebau’s case, the integration of Double Loader and advanced software provided significant value beyond the initial expectations. This experience has further enhanced our expertise in providing scalable, flexible solutions that can adapt to evolving market demands and client needs, ensuring long-term operational success.