A Kassow Robots KR1410 prepares parts for CNC machining at Jules Bertschinger AG. (Image source: Kassow Robots)
The 7-axis KR1410 loads a CNC lathe to enable extended, unattended production. (Image source: Kassow Robots)
When Jules Bertschinger AG, a Swiss precision machining company, needed to boost productivity in its CNC operations without adding staff, it turned to collaborative robotics (cobots). The challenge was finding a solution flexible enough for its diverse small-batch production while robust enough to handle precision components used in everything from rollercoaster safety systems to luxury cruise ships.
Meeting the Challenge
Jules Bertschinger AG specializes in producing machined components, including individual parts and small series production. Its capabilities extend beyond basic machining to include thermal treatments, surface finishing, measurement protocols and restamping. The company's reputation for precision has earned it contracts for safety-critical applications, including seatbelt components for rollercoasters and screw joints for the RMS Queen Mary 2 luxury cruise ship.
The primary challenge facing the company was maximizing utilization of its CNC equipment while optimizing skilled labor deployment. Manual loading and unloading of workpieces was creating bottlenecks and limiting production to standard working hours. Additionally, having skilled machinists tied up with repetitive loading tasks prevented them from focusing on more complex set-up and oversight activities.
Evaluating Solutions
The company considered several approaches to address its productivity challenge. Traditional fixed automation was ruled out due to the inflexibility required for the diverse, small-batch production environment. Adding additional manual labor would increase costs while still limiting production to standard working hours.
After consultation with Swiss integration partner SwissCobots GMBH, Jules Bertschinger AG selected the Kassow Robots KR1410 7-axis cobot. The key differentiator was the robot's 7th axis, which provides greater flexibility for complex part handling and positioning compared to traditional 6-axis systems.
"SwissCobots convinced us that the robots made by Kassow Robots would be the best package for us because they are strong and flexible and also have a 7th axis," noted the project head at Jules Bertschinger. "Innovation is always the 'icing on the cake' for us. It was a good fit."
Implementation and Results
The KR1410 was integrated into the company's CNC lathe operations with minimal disruption. The implementation required only a one-day training program, and the cobot was quickly integrated into existing processes without significant downtime.
The automated process follows a precise eight-step cycle:
1: The workpiece is removed from the workbench
2: The CNC lathe cleans the chuck and prepares for workpiece insertion
3: The KR1410 inserts the workpiece into the CNC lathe
4: The cobot waits in position during the machining cycle
5: The CNC lathe cleans the workpiece and prepares for removal
6: The KR1410 removes the finished workpiece
7: The CNC lathe cleans the chuck and prepares for the next workpiece while the cobot returns the finished part to the workbench
8: The process repeats automatically.
The results have exceeded expectations. "We have dramatically increased our productivity because, in part, the cobot keeps on working even after we go home in the evening," said the project head.
This extended operation capability allows the company to maximize equipment utilization without requiring additional shifts or overtime costs.
Technical Specifications
The KR1410 cobot features seven axes of movement, providing enhanced flexibility for complex part handling. The system is equipped with a SwissCobots pneumatic gripper specifically designed for the application. The cobot's collaborative design allows it to work safely alongside human operators without requiring safety caging, making it suited for the company's existing floor layout.
The 7th axis proves particularly valuable in CNC loading applications, where the additional degree of freedom enables the robot to approach workpieces and machine chucks from optimal angles, regardless of part geometry or fixture configuration.
Impact on Workforce
Rather than displacing workers, the automation has enhanced job satisfaction and productivity. The skilled machinist previously responsible for loading and unloading operations has been reassigned to more engaging tasks, including machine set-up, quality control and oversight of multiple operations.
"The employee who used to do this job is really happy as well because he can work on more interesting jobs," reported the project head.
This redeployment of skilled labor to higher-value activities has improved productivity and employee satisfaction while maintaining the company's commitment to precision manufacturing.
Looking Forward
The successful implementation of the KR1410 has positioned Jules Bertschinger AG for continued growth in precision manufacturing. The combination of extended operating hours, improved labor utilization and maintained quality standards provides a competitive advantage in serving demanding applications across multiple industries.
For manufacturers considering similar automation investments, the Jules Bertschinger case demonstrates that cobots can deliver significant productivity improvements while enhancing rather than replacing skilled workers. The key is selecting systems with the flexibility to handle diverse production requirements while providing the reliability necessary for precision manufacturing applications.
The company's experience with the KR1410 illustrates how the additional 7th axis can provide crucial flexibility advantages in real-world manufacturing environments, making cobots a viable solution even for complex, precision-critical applications.
For more information contact:
Kassow Robots
www.kassowrobots.com/partners
Jules Bertschinger AG
www.cnc-bertschinger.ch