PÖTTINGER Landtechnik GmbH, Grieskirchen, Austria, manufactures machines and equipment for grassland, farming, and digital agricultural engineering. Whether it is mowing units, loading vehicles, plows, cultivators, or assistance systems and software – all products are cutting-edge technology. Jörg Lechner, Head of Production and Materials Management, says: “As a family- owned company, we attach importance to sustainability, quality, and longterm thinking – values which are directly reflected in our production philosophy.”
This includes as a central principle highly flexible production with the capability to deliver solutions to customers’ specific requirements. Instead of producing to stock, all products are manufactured in a weekly cycle and can be adapted depending on market demand. This can be clearly seen in the manufacture of plows, where the variety is so huge that there are hardly two identical machines. The PÖTTINGER Engineering Department provides the basis for this customization with a cleverly designed modular system, which enables the late creation of variants and just-in-time manufacturing despite high complexity. For almost 20 years PÖTTINGER has been relying on an automated plant with four machining centers and pallet rack system in mechanical production. Thus, for a long time PÖTTINGER was a pioneer in flexible production. But five years ago the time had come to find a new solution that would once again push the company ahead in terms of production technology.
On the search for a robust, precise, and flexible production system
The range of parts to be produced is huge: It extends from simple lugs made from structural steel with a weight of around 300 g through to complex gearbox housings made from cast blanks weighing up to 27 kg. Welded frame parts with a length of almost 900 mm also have to be cut on the plant. The required precision is also challenging. For instance, μm tolerances must be observed for gearbox housings. Iskender Merkezoglu, Head of Mechanical Production, explains: “This requires both robust and precise machining centers.”
A retrofit of the old plant was quickly dismissed as this would have taken too long. Problems would also arise from different software versions. Instead, PÖTTINGER decided on a complete exchange during ongoing operations – a“Big Bang”.
Machine manufacturer Starrag was awarded the contract with its horizontal machining centers Heckert H75. The machines developed in the Chemnitz factory impressed with their larger working space and collision circle diameter with a smaller footprint at the same time compared to corresponding machines. “This is an important advantage taking into account our confined spatial conditions. Also looking into the future, because our parts will probably grow in size and complexity”, adds Iskender Merkezoglu. Raimund Hohensinn, who is responsible for overall production at PÖTTINGER, adds: “The Starrag high-end machining center is also extremely energy-efficient, which really suits us. Because at PÖTTINGER we attach huge importance to the economical use of energy.”
As an automation partner, PÖTTINGER chose PROMOT Automation GmbH, Roitham, who together with Starrag offer a decisive advantage: tool management with optimal price-performance ratio. “For its Heckert H75 machines, Starrag offers an affordable tool magazine with 260 positions,” says Iskender Merkezoglu. “As PROMOT can link the magazines of the four machines via its ‘Toolmaster’ gantry loader, 1040 tools in total are available to us. We can exchange them between the four machines as required.” This saves costs and opens up new opportunities in production planning. Because the production control system can reassign the components to a free machine at any time and with minimum effort. Iskender Merkezoglu points out that the tool data on each machine is also available immediately. This is made possible by a Balluff chip recorded by the presetting device and integrated in the toolholder.
“In the end the deciding factor for the Starrag/PROMOT solution was the complete package of technology, efficiency, and cooperation”, sums up Production Manager Raimund Hohensinn. “Starrag assisted us greatly in the project phase and provided answers quickly. This created trust. The same also applies to PROMOT. As a team, we worked really well from the project planning stage through to commissioning.”
