Greipl Group: Transparent production and measurable efficiency through Connected Manufacturing

The headquarters of the Greipl Group is located in the Bavarian Forest. What began years ago as a traditional sheet metal manufacturing company is now a state-of-the-art system supplier for demanding industries such as medical and measurement technology.
“To successfully shape this change, you need partners who not only deliver, but also think ahead – especially when it comes to digitalisation”, explains Managing Director Jürgen Greipl.

Challenges in production 

The Greipl Group is a prime example of many companies undergoing the transition to smart factories. Stefan Reischl, Production Manager at the Greipl Group, describes the desire for tool management as follows:

“We wanted to significantly increase our overall equipment efficiency while minimising set-up times. In our fields, especially in measurement technology, every minute of downtime counts.”

In addition, error prevention played a central role:
“It was important to us that every employee works with the right tools, the correct data and the appropriate programme at all times. There can be no uncertainties in manufacturing.”

The shortage of skilled workers also had an impact: New employees had to be trained more quickly without compromising quality. Training costs and training times are reduced, while transparency across all manufacturing processes is increased, enabling new employees to be deployed in production more quickly.

The solution: Connected Manufacturing 

After an intensive comparison of various systems, the Greipl Group opted for the software solution Connected Manufacturing from the Hoffmann Group.
We looked at various suppliers, weighed up the pros and cons, and ultimately decided on the Hoffmann Group. “The solution was not only cost-effective, but also collaborative and straightforward – that was important to us”, says Stefan Reischl.

Connected Manufacturing connects machines, tools and employees to form an integrated system. The milling tools are serialised and can therefore be clearly identified. “Each chip has its own ID. This means we always know where each tool is located and what data is behind it. The software automatically links the tool to the machine – the data is entered directly into the control system, making the set-up process reliable”, explains Mario Sonndorfer.

Fabian Köglmeier, Process Consultant Digital Products, adds that thanks to the long-standing partnership, both parties always approached challenges during the implementation of the project with openness and a focus on finding solutions. For example, an ERP connection was not possible, but it was then possible to jointly ensure implementation via a CAD/CAM interface. To make optimal use of CM, additional holders were also balanced, with our specialists providing the best possible support.

Digitalisation with tangible added value 

The change quickly brought visible success:

• Less set-up time, more productivity: Automatic data collection through automated net requirement lists and live stock locations saves valuable time in production every day by eliminating time-consuming searches.
• Error-free production processes: The structured storage of programmes ensures that the correct production programme is always loaded, minimising operating errors.
• Induction process for new employees: Illustrated instructions and intuitive user interfaces enable new employees to become productive more quickly.
• Greater audit and process reliability: In medical technology, where traceability and documentation are essential, the Greipl Group impressed with CM during customer and certification audits.

Long-standing partnership that pays off 

The long-standing partnership was crucial in this regard, adds Fabian Köglmeier, process consultant for digital products:
Even in phases when unexpected hurdles arose – such as the unfeasible ERP connection – we always dealt with each other openly, transparently and in a solution-oriented manner.

Together, we found a viable alternative in the simple order planning feature integrated into CM and were also able to successfully integrate the Esprit CAD/CAM interface. Through additional procurement and expansion of tool holders in close cooperation with the regional sales manager and application engineer, we were able to exploit the full potential of CM at Greipl. Not only was the project successfully implemented, but cooperation was also further strengthened.