ROLEC optimizes work processes for employees
ROLEC, a leading manufacturer for the housing of industrial devices, has boosted production efficiency through the use of SHERPA robots.
With roots dating back to the 1960s, founder Friedhelm Rose revolutionized the industry by developing the world’s first sealed aluminum housing. Since then, the family-run company has continually evolved, becoming a top producer of HMI enclosures and support arm systems. The innovative spirit of Friedhelm Rose lives on today, leading to groundbreaking products such as the profiPLUS support arm system and the aluDOOR series, which won the German Innovation Award in 2023.
All ROLEC housings are produced using cutting-edge machinery. Precise CNC techniques drill or mill fine tolerances and custom cutouts to meet individual requirements, effortlessly fulfilling even complex machining demands.
Before Automation…
The production of custom aluminum housings for electrical and electronic components was labor-intensive.
Some of these aluminum housings were processed on HAAS VF-3SS machines, using a mechanical four-jaw chuck from HWR to prevent clamping marks on the thin-walled geometry and ensure ROLEC’s premium quality promise. However, the machining centers lacked media union on the fourth axis to operate the clamping device.
Although production processes were stable, machine operators often worked elsewhere during long production runs. When the machining program finished, the spindle regularly sat idle until an operator noticed the end, cleaned the finished part, and restocked the machine. To address this, the production team aimed to increase staffing efficiency and maximize spindle uptime. The technological challenge was automating the proven clamping technique without altering the established process.
The Solution…
The answer came in the form of a SherpaLoader® M25 with an electric spindle drive. Tasks were redistributed: continuous material staging and supply were handled by trained employees, allowing skilled machinists to focus on production quality and automation.
In the new process, a SpaceBox is loaded with raw material. After completing the current job, the operator replaces the SpaceBox with a new one using a pallet jack, so production resumes immediately. Alternatively, the SpaceBox can remain in place while processed parts are swapped for new raw materials. The operator selects the next job in the dialog control system, and the robot takes over: picking up parts, placing them in the pre-stamping station, and then into the machine vise. The workpiece is clamped by a torque wrench mounted on the robot. Finished parts are automatically cleaned with compressed air and placed back into the SpaceBox by the robot.
A key challenge in the automation process was preventing clamping marks. The gripper’s clamping force was applied through four polyurethane inserts, specially tailored to this application during the project phase, ensuring that ROLEC’s premium quality was maintained throughout automation.
With around 70 housings in the SpaceBox, the system is designed to never sit idle waiting for an operator. Staffing requirements on the automated machines have been reduced by more than 50%, providing a significant competitive advantage and freeing up employees for other tasks. Additionally, the ability to run unmanned night shifts with the robot producing output has reduced the ROI to less than two years.
Matthias Rose, Managing Director:
“Our operating costs are heavily dependent on personnel. Therefore, our goal was to enhance the productivity of our skilled and experienced workers. Today, our employees manage two additional production machines. Due to the short payback period, we quickly purchased a second CNC automation from SHERPA. And we plan to automate more machines in the future.”
14 hours more running time per day
Schöbel Hermann CNC-Frästechnik GmbH…
is the preferred choice for many renowned machining companies, particularly for prototypes and series of 1 to 10,000 parts. This reputation has only grown since Johannes Seilbeck and Martin Herzog took over the company from its founder. Recognizing the potential to transform a small gem into something bigger, they saw the value of digital automation.
Before Automation…
Only five employees worked in production, and despite their extensive experience and expertise in the medical technology, mechanical engineering, and consumer industries, they were limited by capacity. The spindle of the 5-axis machining center MIKRON HEM 500 U was only 75% utilized and remained idle for 18 hours a day. The challenge was to double spindle hours without hiring additional staff.
The Solution…
Upon taking over the company, the first robot was introduced—marking the beginning of a technological leap that the previous owner had neither considered feasible nor dared to implement.
The existing MIKRON HEM 500 U machine was in no way prepared for automation. It lacked an automation interface and a door drive, and there were no free media channels on the 4th and 5th axes, which would have been required to operate a pneumatic or hydraulic clamping device. Retrofitting by the original machine manufacturer was not an option due to lead time and costs. SHERPA provided a complete, one-stop solution with the SherpaLoader® M20, equipped with an electric spindle drive, along with an electric door automation and a robot interface. This allowed the existing clamping technology to be seamlessly integrated into the automation, retaining proven machining parameters, making the transition to automation smooth. Automation now begins with batch sizes of just 10 parts, and due to its robust operation, it ends at series of 50,000 parts per year.
Within a year, the effective spindle time increased from 6 to over 20 hours per day. The automation even ran without staff for several weekends. Schöbel is a perfect example that even small companies can automate and significantly enhance their competitiveness.
Johannes Seilbeck, Managing Director:
“The robot has more than doubled revenue of our automated cnc machine. This is both a success and a motivation for us. That’s why we’ve just invested in a new machining center from HERMLE—and another SherpaLoader.”
Delivery reliability increased without additional skilled workers
CNC-Fertigungstechnik Liebl…
specializes in manufacturing precision parts of special-purpose machine. Located in Gebesee, a village of 2,000 residents in the Thuringian Basin, the shortage of skilled labor is especially evident. In 2023, 49.5% of all open positions in the area lacked qualified applicants, and projections for 2035 show little improvement.
The goal of owner Rene Liebl is to secure local production in Gebesee by decoupling production throughput from staffing levels, allowing short-term orders to be fulfilled regardless of personnel availability.
Before Automation…
Fluctuating demand was, and still is, central to the daily business. Planned orders often don’t match reality. Customers, especially with urgent requests, expect deliveries within a few days or even immediately after the weekend. For rush orders, no operators were available to work late or night shifts.
The Solution…
was a CNC automation that works even when the operators have gone home. The challenge was to automate a vertical MAZAK machining center, model VCN-530C. The machine was retrofitted with a robot interface and two pneumatic clamping devices. The robot control system manages the clamping device, minimizing retrofitting costs. To further extend autonomous runtime, the SherpaLoader® was equipped with a repositioning station, allowing both the front and back sides of parts to be processed in one run.
The SpaceBox, serving as the storage unit for material staging, holds over 400 raw parts measuring 60 x 100 x 35 mm, enabling more than 60 hours of autonomous operation.
Without incurring additional shift premiums, a robot now handles rush orders overnight or series production over the weekend, ensuring parts are ready for delivery by the next working day.
Operators are not only relieved of night shifts, but also benefit from easier order preparation: Raw material is no longer picked by machine operators but by warehouse staff. By decoupling logistics and production, material is now prepared in the warehouse, rather than in front of the machine.
The secret to productivity lies not in speed but in the stability and consistency of operations. While an operator can only work one shift, a robot can run up to three—without breaks and at a constant speed. For suitable orders, the robot operates 100 hours per week or more.
Rene Liebl, Owner:
“At our Gebesee location, qualified machine operators are scarce. Improving delivery reliability was possible only with the support of a robot. Simply put, we can’t afford not to automate our CNC machines!”
