A good step toward robotics in frame production

Automation as answer to shortage of skilled workers

At German window frame manufacturer Gerdes Fenster und Türen, robots have made their first appearance in production. After a good month of installation, testing and commissioning, the robots have been fully integrated into the production process since last April. This has brought the company a decisive step closer to its goal of housing in Lengerich one of the most modern window production facilities in Europe!

High investment in forward-looking technologies 

The decision to invest in automation solutions was already made in the planning phase of the new hall. The new hall expanded the existing production by 3,700 m² by 2022. "This gave us the opportunity not only to increase our production capacity and number of employees, but also to optimally upgrade our production technology," says procurator Peter Simon-Höke. 

Robotics for employee well-being

Together with moduco GmbH, a specialist for production modules from Lingen, Germany, activities in production were identified where automation would make sense. Always central: the employees. 

Simon-Höke explains: "The plastic profiles from which we manufacture our custom window frames weigh up to 30 kg and are becoming increasingly heavy. Our goal was therefore to automate physically demanding, ergonomically unfavorable and monotonous work for the benefit of our employees and to create space for demanding manual work and craftsmanship."

Automation as answer to skilled labor shortage

According to director Thomas Gerdes, the robots are also an answer to the current shortage of skilled workers: "We have grown strongly in recent years and currently have 110 employees. But the lack of skilled employees is also evident in our company. The situation will only become more acute in the coming years given demographic changes. Therefore, robots - in addition to measures and investments in the areas of employer branding and recruitment - are an important building block to remain competitive and enable further growth in the future as well."

Collaboration 

In the planning and commissioning of the robotic system, the company cooperated with moduco. "The framework conditions for automation were challenging," reports Stephan Feldker, founder and managing director of moduco. And he explains: "Gerdes produces custom frames and doors. Therefore, flexible and configurable automation solutions were needed. And we were able to achieve that with the systems from the manufacturers fruitcore robotics and KUKA."

Robots in window frame production

Since April, a customized automation solution consisting of standardized modules and three robots has been integrated into production: two HORST 600 type industrial robots from fruitcore robotics and one robot from KUKA. 

The robots essentially perform the following tasks:

-Picking up profiles from two Thorwesten profile machining centers;

-Positioning and screwing of locking elements (both "normal" locking plates and security locking plates);

-Loading the profiles with assembled locking elements into/onto the transport carts (all four parts that make up a sash or frame, in one compartment).

Then an employee takes the full transport carts to one of the three HVL milling machines or to one of the welding machines or welding lines. 

Further planning for forward-looking technologies

The balance sheet after the first few weeks of "normal operation" is consistently positive. "Of course there are still some teething problems to solve," says Simon-Höke. "But even the first period of 'normal operation' indicates that the investments have paid off and form a good basis for the coming years."

And he emphasizes, "The future of our window production will undoubtedly be determined by the integration of robots and automated systems. This is why we continue to invest in forward-looking technologies and automation."

Open Day

On June 4, Gerdes held an open day in Lengerich. Interested visitors - and there were large numbers of them - participated very actively between 11 a.m. and 6 p.m. in the various fascinating tours of the departments where modern window and door production takes place. Among others, Sales and Marketing Manager Anthonius Gabeler was the guide, who like the other colleagues/guides managed to excite and inspire visitors with his stories every hour. But that was not all: the visitors also got a useful insight into the new robotic system. 

However, there was much more: the new showroom could be shown, there were also various break-in tests and demonstrations. Thomas: "Naturally, the beer garden was also well visited. Plenty of good food and drink. It was fun to see the children of our colleagues and associates at work with all the games we had set up: from the bouncy castle to soccer darts and of course the mini forklift track! We saw many young new forklift talents!"

Thomas concludes: "It is always good to have a conversation with your network of contacts and to tell them what you do and how you do it. The questions we got were great and to be honest: that also gave us some inspiration. All in all a great open day and as far as I'm concerned definitely worth repeating.