EU funds

Project implemented with European Union funds under the European Funds for Eastern Poland Programme 2021-2027 | Priority: Entrepreneurship and Innovation | Measure: Automation and Robotization in SMEs | Call number: FEPW.01.02-IP.01-001/23

The investment concerns the implementation of recommended actions - included in the enterprise transformation roadmap - enabling the introduction of process automation and robotization into the plant - including the implementation of process | product innovations.

The technological transformation is linked to the implementation of Industry 4.0 solutions, which will directly contribute to the positive transformation of the Podkarpackie Voivodeship towards sustainable development. The project is based, among other things, on the robotization of key production processes at ZMP SARD using a tailor-made mobile robotic station designed to perform various tasks, such as comprehensive measurement of details and elements with complex geometry created using CNC technology, unloading and loading of details and elements to and from the machine, and fast and efficient packaging of details and elements. Ultimately, an integrated system for manufacturing high-quality precision-turned metal details and elements, implemented through the combination of advanced CNC machines, a multifunctional 6-axis industrial robot with a maximum position repeatability of +|– 0.03 mm, a vision system for scanning details, a measurement system, control and CAM systems, and a tailor-made machine monitoring system, will ensure effective and efficient metal production and improve the quality of manufactured parts. metal elements with complex geometry - with 100% repeatability and accuracy of execution.

The project's goal is to positively transform the plant based on the automation of key production processes. The project is crucial for transforming production processes, positively impacting the degree of Industry 4.0 technology adoption within the plant and improving employee employment conditions through automation and robotization. Flexible metal production will be introduced, continuously adapted to customer requirements and achieving increasingly higher performance indicators, resulting in high production efficiency while minimizing costs. The purchase of a custom-made 6-axis robot, dedicated machinery, and ICT will enable the implementation of Industry 4.0 solutions, optimizing metal production, increasing production quality and efficiency, and significantly increasing the plant's competitiveness, supporting the circular economy.

The end result of the transformation towards Industry 4.0 will enable the plant to expand its offer with innovative product services, enter new markets (automotive | aviation) and open up to PREMIUM customer service.

production characterized by 100% repeatability and quality guarantee of manufactured details and metal elements - achieved as a result of the implementation of HSM [High Speed Machining], i.e. fast machining using high feeds and rotational speeds

carried out using longitudinal automatic lathes with a rotation speed of transverse rotary tools of 6,000 m-1,

a turning center with two spindles and two heads (*with a minimum speed of driven tools of 8000 rpm), as well as a highly specialized, tailor-made robotic station with a vision system for scanning details [so-called Bin Picking] responsible for the quality control of hundreds or even thousands of details and metal elements on the production line.

As part of the FEPW.01.02-IP.01-0047/23 project Implemented under the European Funds for Eastern Poland 2021-2027 program | Priority Entrepreneurship and Innovation | Measure Automation and robotization in SMEs, Duszkiewicz Roman Precision Mechanics Plant "SARD" has introduced the following innovations to the plant's offer:

Process innovation | integrated system for manufacturing high-quality, precisely turned metal parts and components | implemented thanks to the combination of advanced CNC machines, a multifunctional 6-axis industrial robot with a maximum position repeatability of +|– 0.03 mm, a vision system for scanning parts, a measuring system for automatic measurement of parts, control systems and CAM systems, a tailor-made system for monitoring the operation of production machines and other systems.
Product Innovation | CNC Production Services: Production of highly complex details and multi-series components dedicated to the automotive and aviation industries, among others, characterized by 100% repeatability and quality guarantee thanks to the use of a multi-tasking robotic station.
Organizational innovation | production combined with optimized real-time order scheduling, ensuring availability of the offer in an "on-demand" system [instant manufacturing]
Marketing innovation | new promotion method – based on the introduction of “on demand” production [instant manufacturing] combined with involving the customer in the order fulfillment process from the very beginning | discounts on wholesale orders in line with the loyalty program.

Roman Duszkiewicz, Zakład Mechanicniki Precyzyjnej "SARD", in connection with the implementation of the investment, implemented the recommended actions included in the company's transformation roadmap, allowing for the introduction of automation and robotization of production processes, including process and product innovations, to the plant.

Robotization of key production processes has been introduced at ZMP SARD using a tailor-made mobile, robotic automatic station designed to perform various tasks, such as comprehensive measurement of details and elements with complex geometry created using CNC technology, loading and unloading of details to and from the machine, as well as quick and efficient packaging of details and elements.

The integrated system for manufacturing high-quality, precisely turned metal parts and components is implemented thanks to the combination of advanced CNC machines, a multifunctional 6-axis industrial robot with a position repeatability of up to ±0.03 mm, a vision system for scanning parts, a measuring system, control systems and a CAM system, as well as a tailor-made system for monitoring the operation of machines in production, ensuring effective and efficient metal production and 100% repeatability and accuracy of manufacturing metal parts and components with complex geometry.

automation of order fulfillment from the moment of order acceptance – metal production scheduling | queuing production orders and subsequently transferring them to production, which guarantees immediate real-time organization and optimization of metal production processes, with automated monitoring of the operation of machines | robots available in the plant | monitoring of manufacturing processes based on data processed in real time;
automation | robotization of the metal production process – in relation to technological stages | internal transport - unloading and loading of details | metal elements from and to the machine | quality control of produced details | metal elements, packaging of details | metal elements;

the combination of precise and highly efficient automatic mechanical processing with a mobile robotic automatic station [ensuring the implementation of various tasks – in a robotic manner] and an advanced measuring machine [guaranteeing a minimum position measurement accuracy of max. ±2.5 m *1 in high accuracy], supported by a "tailor-made" system monitoring the operation of machines | robot in production - created intelligent production based on the flexible use of resources – with greater transparency of order execution;

Flexible metal production has been introduced – continuously adapted to customer requirements and to increasingly higher performance indicators, which translates into high production efficiency while minimizing costs.

The entire transformation of the Duszkiewicz Roman Plant of Precision Mechanics "SARD" to the 4.0 model is a significant change from the point of view of the plant and the production and business processes implemented in the enterprise.

Placing an order by the Customer.
Acceptance of the order for execution by ZMP SARD.
Machining by turning using professional automatic lathes with an automatic bar magazine | with a maximum machining diameter of Ø 20 mm and a rotation speed of the transverse rotary tools of 6,000 m-1 and a turning center with two spindles and two heads – enabling the creation of details and metal elements with narrow tolerances.
Key stage of order execution: quality control of metal details and elements using a robotic station based on a multi-task 6-axis robot equipped with a random feeder for selecting metal details and elements, dedicated to large-scale production and short production cycles | stages:
random picking of a workpiece by the robot without first placing it on the table [picking a workpiece from a basket | from a belt | from a feeder – Bin Picking];
scanning the detail for the purpose of visual analysis of the detail | enabling non-contact checking of the accuracy and quality of the manufactured detail | successively selecting the detail for measurement control [*the robot places the detail on the measuring station and starts picking the next detail for visual analysis]
precise dimensioning of many details in the system's field of view is performed using an advanced measuring machine | goal: each of the manufactured details and metal elements of a given series | of a given order is identical and manufactured with high accuracy and ultra-precision, from the first to the thousandth piece | precise dimensioning is to complement the visual quality control processes carried out by the vision system;
stage of packing the detail | arranging the detail in a package for sale;
* cycle programmed individually according to assigned orders – with the possibility of 24/7 execution | cycle designed to ensure flexibility and the ability to handle various details | regardless of the complexity of the geometry or the number of details;
Completion of quality control. Confirmation of consistent quality for each detail and metal component assigned to the order.
Order picking | Arranging the item into packages for sale. Order shipping as part of the implemented fast and on-time synchronous deliveries ["on demand" – instant manufacturing].

EU FUNDS

Increased competitiveness of the plant through the implementation of innovative solutions in the area of Industry 4.0 based on a multi-task robotic station with a vision system for scanning metal details | elements.

NEW COMMERCIAL OFFER INNOVATIVE CNC MANUFACTURING SERVICES

Department of Precision Mechanics "SARD" Roman Duszkiewicz

PROJECT RESULT