From a raw part to a component ready for installation.

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A shortage of skilled workers, rising labor costs, shrinking batch sizes, and increasingly disrupted global supply chains call for new local production concepts. Today, companies no longer need isolated machine automation, but rather end-to-end processes with as little manual intervention as possible.

In many manufacturing processes, the actual machining accounts for only a portion of the total lead time. The steps of machining, deburring, washing, measuring, and marking result in unnecessary transport, wait times, and manual interventions. This is exactly where the joint solution from WASSERMANN TECHNOLOGIE and JTA Connection comes in.

Unlike traditional workpiece automation systems, this system also processes small production runs with lot sizes of fewer than ten pieces. Raw parts are retrieved directly from mesh bins, automatically identified, and fully machined into components ready for installation.

And these are the results that can be achieved through end-to-end automation:

  • Significantly shorter turnaround times
  • Space-saving by eliminating space-intensive intermediate storage facilities
  • Minimized handling costs through one-time data entry in the overall process
  • Longer operating hours due to unmanned shifts and weekend operations
  • Proactive resource checks prevent unplanned downtime
  • Supporting Cross-Plant Digitalization Through an Integrated Cell Computer
  • Also available for retrofitting existing machines

WORK-S TERMINAL as a storage unit for pre-set workpieces

To minimize setup times and enable unmanned shifts, the automation cell shown here features a WASSERMANN pallet carousel with 6 pallet stations and a setup station that operates in parallel with production. Thanks to the telescopic forks in the handling device, the WORK-S can be designed to be particularly space-saving. Transfer capacities of 300, 400, and 800 kg are available. The unit is managed and operated via the central Nexus control system.

Robots with Simple Teach-in Programming

For all handling tasks outside the pallet storage area, JTA Connection integrates a 6-axis Fanuc robot into the cell. It is equipped with multiple gripping tongs, which are stored in a magazine for fully automated replacement. This enables changeovers for handling different workpieces in less than 1 minute.

To automatically remove parts from the mesh box, the robot is equipped with a camera system and specialized software developed by JTA that enables it to reliably identify the parts even when they are in random orientations.

When a new component is introduced, the robot is programmed using easy-to-understand teaching steps that the operator can perform on their own without assistance from the manufacturer.

In addition to loading and unloading the fixtures at the setup station, the robot also performs all other handling operations within the cell. The clamping and unclamping of the fixtures is carried out by a screw moduleintegrated into the robot. This includes feeding the deburring, measuring, washing, and marking stations. The result is a fully automated process that produces workpieces ready to be incorporated directly into the final product during assembly.

Integration with Intralogistics

Workpieces that have gone through the entire process in the manufacturing cell are placed by the robot in layers inside finished-part containers.

For further processing in the factory—such as painting or assembly—components can be retrieved using AMRs or AGVs, or manually with a forklift. To supply raw-part containers and remove finished-part pallets, the NEXUS control system triggers the corresponding calls fully automatically to ensure continuous production during unmanned shifts.

Planning production proactively and checking the necessary resources is essential for avoiding unplanned downtime. This is especially true when very small orders, in any order, dictate day-to-day production.

The NEXUS control system is responsible for initiating production orders and, at the same time, checks whether all necessary production resources are available in the cell. This step makes it clear, as soon as a new order is created, whether the components can be fully machined or whether, for example, a sister tool or a CNC program needs to be reloaded. This resource check is an important prerequisite for achieving a high utilization rate throughout the entire system.

User acceptance stems from intuitive usability. That is exactly what the Nexus control system is designed for: with a clearly structured menu system, intelligent subroutine technology, and logically linked drop-down functions.

Whether you’re creating new parts or remanufacturing existing workpieces, the control system provides direct and quick access to all relevant functions at all times.

Standardized interfaces such as OPC UA enable integration with other IT systems within the company. This ensures end-to-end digitalization in every case.

Conclusion

The future of automation no longer ends at the machine tool. Only when machining, deburring, washing, measuring, marking, and intralogistics merge into a seamless process does the full economic potential emerge. WASSERMANN TechnoTECHNOLOGIE and JTA Connection will be presenting exactly this approach live at AMB 2026.

You can find us in the Oskar Lapp Hall (Hall 6), Booth No. 6D30.