In the planning department, we create the system concept with an initial profile of the system that includes the layout of the production systems as a 2D and 3D model in ProcessDesigner according to individual customer requirements.

Furthermore, there is delivery-date monitoring of the individual components as well as complete support of the project from the concept through to handover to the end customer.

The planning department also ensures the complete documentation of the system.

The design department designs all individual components of the automated system in detail completely as 3D designs in the CAD system. This requires close cooperation with our simulation department to ensure the functionality of the mechanical, electrical and pneumatic parts of the system. We use the latest CAE system – EPLAN Fluid – to create pneumatic circuit diagrams.

Furthermore, 2D production documentation and BOMs are created here, and communication with the end customer occurs during the presentation and approval of concepts for the system.

The main task of the simulation department is to ensure the functionality of automated and robotic lines. The focus is in particular on collision-free and consistent production technologies with the maximum possible utilisation, mainly with robots and workers in the line, in relation to the set production time.

The ability to perform servicing work that enables equipment-maintenance workers to gain access to key components and areas of the line is then checked.

Based on its skills and experience, the simulation department also participates in the actual planning of these production systems. Planning is based on the documentation of the manufactured product, the required production capacity, the required quality and, finally, the location of the means of production.

The production systems we design are largely specific, because they produce subassemblies that include the outer panels of the vehicles themselves. Increased demands are also placed on the surface quality and the entire process has to be planned such that the surface of the panels does not deteriorate.

The main outputs of the simulation include the calculation of the mass loading of robots and the subsequent specification of certain types of robot as well as their percentage load in the process, for example.

Our assembly department takes responsibility for setting up the entire system, from the floor plan to commissioning.

We support and cooperate with all departments and our suppliers throughout the project.

In addition, the construction site warehouse is set up, the inventory of spare parts and tools is regularly checked, and the construction site is managed and monitored with regard to requirements and safety.

All assembly activities are also coordinated here and production at the end customer’s site is supported.

During automation, the safety and control concepts for system planning are created.

The electrical circuit diagrams are completely designed and the necessary technologies specified according to the wishes of our customers.

This is followed by the programming and commissioning of PLC controllers and industrial robots, the programming of manual and automatic modes, and the setting and testing of identification and camera systems.

The latest technologies, such as automated bin picking, are also implemented here. This makes it possible, for example, to produce systems that function completely without operators.

Software for new technologies is also being developed within our group.

The system is fully optimised during commissioning. The aim is to achieve the required product quality before series production begins.

The contours of fixtures are mechanically adapted to achieve the required quality.

In addition, joining technologies such as riveting, gluing and clinching are configured and folding processes are optimised.

Our professional team organises or participates in all technical and quality meetings with the customer or supplier (e.g. parts tables, audits, cubing and master jigs).

Our quality assurance department optimises production systems and sets up production technologies.

Porsche Werkzeugbau in Horná Streda has its own measuring centre, in which tactile measurements and statistical evaluations are carried out. Optical measurement with a mobile measuring system is also possible.

Our metallography lab performs destructive testing of joints (analysis of micrographs) as well as non-destructive testing by means of ultrasound.

Furthermore, radii and design lines can be evaluated and various analyses can be carried out with regard to the surface quality of manufactured parts.