SEW-Eurodrive receives Factory of the Year award

KASTO Maschinenbau automation assists Germany’s winner of Outstanding Series Production category

SEW-Eurodrive was presented the Factory of the Year award during the 34th Factory of the Year Congress held in Dortmund, Germany, on March 18-19. At the award ceremony, SEW-Eurodrive showcased the Smart Factory North Hall (Halle Nord) located in Graben-Neudorf, near Karlsruhe, illustrating how modern series production is designed.

The global company provides products that are utilized across various industries, including intralogistics, mechanical and plant engineering, as well as conveyor systems. The award-winning North Hall facility in Graben-Neudorf was recognized as one of Germany's most advanced production centers. Technology from KASTO Maschinenbau based in Achern plays a significant role in this acclaimed plant by supplying essential components for production and material flow logistics. Key factors contributing to the award include the plant design, Industry 4.0 methodologies and the implementation of the "never-touch-a-part" principle, which minimizes manual contact with components throughout the entire production process.

SEW-Eurodrive utilizes several automated systems from KASTO to supply its production lines: Central to this global system is a honeycomb storage system that accommodates 5,140 locations for cassettes, each with a load capacity of up to 3 tonnes (Figure 1). Additionally, there is a sawing center with 450 locations for individual bars.

These systems supply eight fully automated circular saws equipped with robotic handling systems, along with an automatic bandsaw designed for large material cross-sections. And there are seven output stations dedicated to material separation.

Thanks to the KASTO Warehouse Management System (WMS), all systems are fully digitally interconnected, enabling the automated system to be operated by as few as four people. KASTO technology ensures that production lines are consistently supplied with materials, as material movements are conducted automatically and according to demand (Figure 2).

The implementation of this significant lighthouse project at KASTO involved nearly all technical divisions, including robotics, sawing technology, storage logistics and software development. This initiative is among the most extensive in the history of the family-owned business.

"We are extremely proud that SEW-Eurodrive has received the Factory of the Year award. Our systems played a crucial role in one of the most innovative factories in Europe. This lighthouse project will always stand out as a significant milestone in the history of KASTO," says Armin Stolzer, managing director of KASTO Maschinenbau (Figure 3).

The award is given by Kearney and Produktion.

KASTO has an engineering tradition that spans more than 180 years. Originally a pioneer in sawing technology, the company has developed sawing, storage and material handling systems. KASTO is at home wherever metal is cut, stored and moved, playing a role in the value chain for a wide range of metal products ranging from chair legs to high-rise building cladding and e-bikes to aircraft. With a broad-minded approach, the company focuses on managing complex large-scale projects, showcasing its exceptional strengths.

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