PENN GmbH site that will house all Austrian production by 2028.
EMAG VL 2 manufacturing systems are fully connected for the automated machining of forged parts in 20-shift operation.
The consistent automation enables PENN to produce competitively even in the high-wage country of Austria.
EMAG VL 3 DUO and VL 2 lathes with TrackMotion system during OP 10/OP 20 machining of automotive components
Finished rotationally symmetrical forgings for the automotive industry after machining on EMAG machines.
View of the production hall with various EMAG machining centers, comprising a total of 43 spindles in the VL 2, VL 3 and VL 5 versions.
Complete process chain: From forged raw-parts (left) through various processing stages to the ready-to-install end product (right)-everything is under one roof at PENN.
The Hatebur AMP70XL forging machine at Penn's Stratzdorf plant is the heart of the production of rotationally symmetrical forgings with a cycle rate of 70 components per minute.
Almost all components for the production tools are manufactured in-house in PENN GmbH's toolmaking department, which allows short reaction times for production adjustments.
The increasing complexity of requirements in metal processing and international cost pressure pose particular challenges for manufacturing companies in high-wage countries. The Austrian company PENN GmbH has established itself as an internationally active metal processor through a high level of vertical integration and consistent automation. Vertical turning machines from EMAG's VL series, which have been in use at PENN for over a decade and have now grown to 43 spindles, play a key role in the production chain.
From Forged Part Production to Complete Machining
Founded in 1965, PENN has grown from a small forging company into a high-tech supplier with over 700 employees. A milestone in the company's history was the investment in a forging plant in 2007, which produces rotationally symmetrical forgings at a rate of up to 70 components per minute. This corresponds to an annual volume of up to 10 million forged parts.
The high production volume requires equally efficient machining technology. This is where the machines from EMAG come into play, as Managing Director Gernot Penn explained: "The majority of our forged parts are machined in-house. We use our connected EMAG VL manufacturing systems for this, which run practically around the clock."
Customized Machine Concepts for Large-Scale Production
The cooperation between PENN and EMAG began in 2010. The first systems-two connected VL 5i machines-were put into operation in 2011 and used for the machining of rotationally symmetrical forgings for the automotive industry. This was followed in 2014 by the first VL 2 machines for gear blanks, also for the automotive industry. The machine portfolio has been systematically expanded over the years and now includes over 30 EMAG VL 2 machines for machining small- to medium-sized rotationally symmetrical workpieces, VL 2 DUO line machines with TrackMotion system for automated link-up, VL 3 DUO machines for larger workpieces and VL 5i systems for machining complex geometries.
Technical Features of the EMAG VL Series at PENN
The VL series from EMAG is characterized by its vertical design, which enables a particularly compact footprint. The vertical turning machines offer several technical advantages that are crucial for PENN's production requirements. First and foremost is the vertical pick-up spindle, where workpieces are picked up directly from the work spindle by integrated conveyor belts, eliminating the need for additional handling systems and minimizing nonproductive time. The TrackMotion system allows several machines to be linked up to form a flexible production line, ensuring an automated workpiece flow.
The EMAG turret with turning and driven tools also enables complete machining in a single set-up of complex components. Lastly, the machine body made of mineral casting and the vertical concept offer high thermal stability, which is particularly important in 20-shift operation.
Maximum Machine Availability
For a company like PENN, which has to hold its own against international competitors in the high-wage country of Austria, plant availability is a decisive economic factor.
"We work in 20-shift operation for most of the year. With this production volume, machine availability and reliability are absolutely crucial," said Penn.
EMAG machines achieve a high level of availability at PENN. This is made possible by several factors: The robust machine design with high rigidity forms the basis. In addition, there are preventive maintenance concepts that minimize downtimes, as well as fast service support from EMAG. Additionally, the well-trained maintenance personnel at PENN also contribute to the high availability.
"As far as service is concerned: cheaper is always possible, there are cheaper machines everywhere. But it is the service that makes the decisive difference. You have to look at the machines in terms of life cycle costs," explained Penn. The close cooperation between the EMAG service team and the PENN maintenance technicians is a key success factor.
Automation as a Competitive Factor
In order to remain competitive despite the higher wage and nonwage labor costs in Austria, PENN also consistently relies on automation.
"To be able to compete internationally, especially with low-wage countries, we need to implement smart automation solutions," said Penn. "In Europe, there are countries with only 30% of the wage costs of Austria or Germany. We have to compensate for this difference with intelligent automation and high plant availability."
EMAG machines support this approach with their sophisticated automation concepts. The integrated workpiece feeding and removal significantly reduces manual effort. At the same time, the automated measuring technology ensures continuous process monitoring. The interlinking options provided by the TrackMotion system allow a continuous material flow without manual intervention.
These automation solutions enable PENN to use employees primarily for quality monitoring. Penn noted: "Above all, we expect our employees to have a high level of quality awareness. The actual work should be done by the machine. The employee must be able to concentrate on monitoring the quality produced."
Complete Process Chain Under One Roof
A particular advantage of PENN GmbH is its comprehensive vertical integration. From forging production and machining to assembly and final inspection, all process steps are carried out in-house. The EMAG machines are a central element in the value chain.
Future Prospects and Further Development
PENN GmbH plans to merge three of its Austrian sites by 2028, which will mean a significant efficiency boost. EMAG machines will play an important role in this, as their compact design enables high productivity per unit area.
In terms of market development, PENN is positioning itself broadly. "We are not focusing exclusively on the combustion engine or electromobility, but are keeping our eyes open in all directions," said Penn. This flexibility is also reflected in the versatility of EMAG machines, which can be used for a wide variety of workpieces and materials.
Economical Production Through Optimized Machine Systems
"The long-standing collaboration between PENN and EMAG demonstrates how modern machining technology can help to produce competitively even in high-wage countries," said a spokesperson. "By combining high-performance forging systems, highly automated vertical lathes and comprehensive vertical integration, PENN has created a production system that combines maximum efficiency with maximum flexibility. The 43 EMAG spindles in the VL series, some of which are in use around the clock, form the backbone of PENN's machining technology and underline the importance of reliable machine systems for economic success in metalworking."
For more information contact:
PENN GmbH
info@penn.at
www.penn.at
EMAG L.L.C.
38800 Grand River Ave.
Farmington Hills, MI 48335
248-447-7440
info@usa.emag.com
www.emag.com