Sheet metal processing automation line

Dajano Sp. z o.o. is a leading manufacturer of metal baskets and containers for protecting sensitive goods during transport and storage. Dajano Sp. z o.o. is also a respected supplier of steel processing services with many years of experience and an established position. Due to dynamically changing market challenges and a constant drive to improve productivity, Dajano’s owner decided to implement automation in sheet metal processing.

Increased productivity: previously, sheet metal was stored on static racks and transported to the processing stations by forklift trucks. Due to the number of machines (4 BLM laser cutting machines), the logistics involved in delivering the raw material were problematic and time-consuming. Cranes were used to load the laser cutting machines, while collecting the cut parts from the laser tables was done manually. In the steel cutting service industry, in addition to quality, lead time and timeliness are important parameters for customers. In such a structured process, achieving the above was a huge challenge for process managers.

Reduction in the involvement of operators in the production process: the significant number of machines used in the process meant not only complications in the area of logistics, but also the need to involve many laser cutting machine operators and forklifts necessary to meet the production targets (also on 3rd shift and at weekends). The execution of the production plan without the implemented automation depended on the presence and efficient and effective performance of the operators.

Increased production flexibility: in the service cutting industry, frequent changes of the sheet metal range, the realisation of long and short series or even the cutting of single sheets to a specific customer order are everyday reality. A high degree of flexibility is required and the ability to work in a High-Mix Low-Volume model, where ‘change’ is a constant part of the manufacturing process. Operating in such a model, performing many activities manually, is impossible.

After analysing the challenges faced by Dajano in the area of laser sheet metal cutting, a SmartFlow System was designed, consisting of an automated MultiTower sheet metal storage system with a stacker crane with a capacity of over 630 tonnes and a MultiLoader transport system with two independent modules – loading and unloading. The loading module, which transports the raw sheet metal to the laser cutting machines, is equipped with a sheet separation system, sheet thickness measurement and dozens of suction cups providing full flexibility in handling a very wide range of sheet formats – from 0.5 m x 0.5 m to 3 m x 1.5 m.

Three access points (two single- level and one double level) are responsible for transporting the cut parts out of the cutting area. The raw material is loaded into the storage area by a mobile station equipped with a basing and a hydraulic depalletiser, which allows sheet metal to be stored without pallets.

It is worth mentioning that the system is also equipped with an energy recovery module, which is used to power the movement of the stacker crane.

The software supplied by Baumalog is integrated with the Lantek CAD/CAM system, which is responsible for the technological part of the process, including the creation of nesting, queuing, as well as order management and the control system for the four BLM laser cutting machines.

• increase in production efficiency (several times over!) compared to a manual system
• reduction in manpower required for the cutting process
• readiness for flexible production, including efficient execution of
• short series and unit orders (High-Mix Low-Volume)
• elimination of fork-lift truck traffic
• operation of cutting machines without the constant presence of
• operators (including nights and weekends)