Alexander Trost founded the company in Rahden in 2006 with a vertical machining center. Today, the company manufactures products using seven modern CNC machining centers and a team of ten qualified employees in a 1,300 m² facility.

Easier automation with the SherpaLoader®

Making manufacturing tasks as simple as possible is one of the supreme challenges of machining. Automation can play a crucial role here—especially when it prioritizes simplicity. MAFU-SHERPA CNC Automation GmbH demonstrates how camera-guided CNC automation boosts productivity, improves cost-effectiveness, and makes manufacturing workstations more attractive.

Efficient production of small and medium-sized series

“Our daily challenge is to remain competitive. Because the competition is getting tougher and tougher,” emphasizes Alexander Trost, managing director of TROST Zerspanungstechnik GmbH & Co. KG in Rahden. “Our top priority is ensuring trouble-free machine operation while reducing the workload on our operators.” TROST manufactures precision components for general and specialized machine construction, typically in small and medium-sized production runs. For many years, the company has relied on reliable 3- and 5-axis machining centers of HURCO. To reduce setup times and ease the workload on staff, a HURCO VMX 30Ui was automated using the SherpaLoader®.

Automated 5-axis Machining at TROST

At TROST, a SherpaLoader® has been handling workpieces since 2021, from material staging to the finished part. Two table trolleys serve as material storage. A 3D camera system mounted on the robot detects the blanks as they are fed in, regardless of their orientation, eliminating the need for dies or fixed stops. The robot precisely aligns the blank, automatically clamps it in the vise of the HURCO VMX 30Ui, and starts machining. After machining, the SherpaLoader® M20 cleans the workpiece with compressed air, removes it, and immediately loads the next blank. This ensures that loading and unloading operations run synchronously—for maximum spindle runtime and process reliability. “During the day, we’ve reduced our staffing levels, and in the evenings we can continue production unmanned,” reports Trost. “The combination of the HURCO machine and Sherpa automation has proven its worth; since 2024, the next SherpaLoader® has been loading a VMX42 SRti on the production floor—our key to consistent productivity.”

Maximum flexibility through camera control

Whether for milling or turning, the SherpaLoader® systems feature a modular design and support 6-axis robots of 7 to 225 kg. Their 3D vision system and laser system automatically detect parts, adapt to new geometries, and enable changeovers in under five minutes. Workpieces can be loaded flexibly and in a space-saving manner using table trolleys, pallets, or the SpaceBox pull-out system. This camera-based intelligence ensures robust handling, fewer manual interventions, and consistent machine availability—perfect for small and medium-sized production runs.

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August Mink GmbH & Co. KG has been setting standards in the manufacture of innovative brush solutions for decades and, since its founding in 1845, has evolved into the global market leader in modern fiber and brush technology. From a range of well over 250,000 variants, more than a million brushes are produced annually at five manufacturing plants in Göppingen. The continuous expansion of this facility and the industry’s most advanced machinery enable the production of brushes of the highest quality and faster delivery, even for custom-made products.

Before automation

When designing a new production line for thermoplastics, it was clear from the outset that efficient automation was essential. MINK was looking for a solution that would enable continuous production with maximum autonomy, even with multiple product changes each day. Therefore, it was essential to create a large yet flexible material storage system. This is where MAFU-SHERPA’s proven robotics solution came into play.

The Solution

MAFU-SHERPA’s “Stacking” program module provided the ideal solution to this challenge. In this process, blanks are stacked on pallets and made ready for processing. The robot picks them up from a pallet, loads a processing machine, and then unloads the finished parts onto a second pallet, again in stacks. Through close collaboration between MINK and MAFU-SHERPA, adjustments to the design and robot programs made it possible to increase the stacking height to a total of ten levels. A single pallet can now hold over 1,000 parts—significant progress that substantially increases the efficiency of production processes.

Manuel Fischer, Project Manager of MINK:

“I really enjoyed working on this project. With a few small but crucial adjustments, MAFU-SHERPA was able to tailor its standard system very effectively to the specific needs of MINK.”

Florian Andre, CEO of MAFU-SHERPA, also emphasizes the company’s philosophy:

“MAFU-SHERPA provides established standards for loading and unloading CNC-controlled machine tools. To a certain extent, we can accommodate customer requests, as long as the basic principle of ‘fitting the round into the square’ is maintained.”

Greater efficiency,

less labor costs

Thanks to the MAFU-SHERPA robot cell, MINK was able to significantly optimize its workforce allocation in production. Skilled workers can now focus more on quality assurance and value-adding processes, while automation ensures a smooth material flow. Production now runs at maximum efficiency—around the clock.

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The machining of individual parts, prototypes, and small production runs on state-of-the-art machining centers in a climate-controlled environment. Complex geometries, sophisticated 5-axis multi-sided machining, and comprehensive documentation of extremely tight tolerances characterize our day-to-day operations, particularly in the production of precision parts for use in satellite technology.

When one of IPT’s customers significantly increased its order volume, the company faced a critical challenge: How could the existing DECKEL MAHO DMU 60 eVo 5-axis machine be automated cost-effectively?

Before automation

As a contract manufacturer, IPT must plan its investments strategically and find economically viable solutions. An inquiry to the machine manufacturer revealed that the retrofitting required for automation—including rotary feed-throughs on the 4th and 5th—had a limited load capacity. axes, a hydraulic clamping system, an automated machine safety door drive, and a Profibus automation interface—would have cost a high five-figure sum. For a machine that had already been in service for ten years, there was none of this. IPT therefore sought a needs-based alternative—and found it with MAFU-MAFU-SHERPA CNC Automation.

The Solution

Instead of carrying out costly machine modifications, IPT opted for the custom-fit automation solutionSherpaLoader® M25 :

• For processing machines without a rotary feed-through, MAFU-SHERPA installs the RoboBuddy electric torque wrench of ALLMATIC to efficiently automate mechanical vises. This eliminates the need for retrofitting a hydraulic clamping system.
• MAFU-SHERPA supplied a custom I/O interface that was retrofitted for less than half the price of a Profibus interface from the machine manufacturer. This made it possible to implement the automation connection in a cost-effective and flexible manner.
• MAFU-SHERPA has equipped the machine’s existing round door with a personnel-safe door drive that integrates seamlessly into the production process.
• MAFU-SHERPA’s SpaceBox can hold over 500 parts within the space of a euro pallet. This allows the system to run autonomously for more than 8 hours without manual intervention.

Holger Gräbeldinger, Managing Director:

“We started using the MAFU-SHERPA automation system about nine months ago. Today, I can’t even imagine how we would have managed the workload of the automated system if we had to load it by hand.”

Thanks to MAFU-SHERPA, IPT was able to automate its manufacturing process cost-effectively without having to invest in expensive machine modifications. This was a crucial step toward greater efficiency and competitiveness.

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ROLEC traces its roots back to the 1960s. The founder, Friedhelm Rose, revolutionized the industry at that time by developing the world’s first sealed aluminum enclosures. Since then, the family-owned company has continued to evolve and is now one of the leading manufacturers of enclosures, HMI enclosures, and support arm systems. Friedhelm Rose’s innovative spirit lives on today and has led to groundbreaking products such as the profiPLUS support arm system and the aluDOOR enclosure series, which won the German Innovation Award 2023.

All ROLEC enclosures are manufactured using state-of-the-art machinery. Precise CNC technology is used to drill or perform milling on the finest fits and custom cutouts as needed. Even complex product machining requirements are met with ease.

Before automation

The production of custom aluminum enclosures for housing electrical and electronic components was a labor-intensive challenge.

Some of these aluminum housings were machined in a single setup on HAAS VF-3SS machines. The 4-axis machining center was upgraded to a 5-axis machine and operated with a mechanical four-jaw chuck from HWR. This was necessary to avoid clamping marks in the thin-walled geometry and to ensure ROLEC’s commitment to premium quality. The processing machines did not have a media union on the fourth axis for actuating a clamping device.

Although the production processes were running smoothly, the machine operators often took on tasks elsewhere in the production area due to the long processing times. Once the machining program had finished, the machining center’s spindle would therefore regularly remain idle until the operators acknowledged the end of the machining process, cleaned the finished part, and reloaded the machine. Production management therefore sought to optimize personnel allocation and maximize spindle time.

The technological challenge was to automate the proven clamping technology without altering the established clamping process.

The Solution

consisted of a SherpaLoader® M25 with an electric spindle drive. First, the tasks were reassigned: The separation and continuous feeding of material are now carried out by semi-skilled workers, while the qualified machinists focus on production quality and automation.

In the new process, the SpaceBox is loaded with raw material. Once the Current Job is complete, the machine operator in the robot cell can replace the used SpaceBox with a new one containing blank parts—using a pallet jack—and immediately resume production. Alternatively, the SpaceBox can remain in place while the machined parts are replaced with raw blanks. The New Job is selected in the dialog control, and the robot begins work: It picks up the parts, places them in the stamping station, and then into the machine vice. The workpiece is clamped using a torque wrench mounted on the robot. Finished parts are automatically cleaned with compressed air and placed back into the SpaceBox by the robot.

A particular challenge in the automation process was avoiding clamping marks. Force was transmitted to the Gripper via four clamping inserts with a polyurethane surface, the properties of which were specifically tailored to this application during the project phase. This ensured that the automation maintained ROLEC’s consistent premium quality.

The approximately 70 enclosures in the SpaceBox ensure that the system never has to stop and wait for the operator. Staffing levels at the automated systems have dropped by more than 50%, which has led to a significant competitive advantage and given employees more time for other tasks. The fact that the robot cell also operates during unmanned night shifts and generates output during that time is a welcome side effect that has reduced the ROI to less than two years.

Matthias Rose, Managing Director:

“Our operating costs depend heavily on our workforce. That’s why our goal was to increase the productivity of our skilled and experienced workers. Today, our employees operate two additional production machines. Because of the short payback period, we immediately purchased a second CNC automation system of MAFU-SHERPA. And we plan to automate more machines next.”

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is the preferred choice for many renowned machining companies, particularly for prototypes and series of 1 to 10,000 parts. This reputation has only grown since Johannes Seilbeck and Martin Herzog took over the company from its founder. Recognizing the potential to transform a small gem into something bigger, they saw the value of digital automation.

Before automation

Only five employees worked in production. Despite their many years of experience and expertise in the fields of medical technology, mechanical engineering, and the consumer goods industry, they were reaching their limits due to staffing constraints. The spindle of the MIKRON HEM 500 U 5-axis machining center was operating at only 25% capacity and was idle for 18 hours a day. The challenge was to double the spindle hours without hiring additional staff.

The Solution

Upon taking over the company, the first robot was introduced—marking the beginning of a technological leap that the previous owner had neither considered feasible nor dared to implement.

The existing MIKRON HEM 500 U machine was in no way prepared for automation. It had neither an automation interface nor a door drive. In addition, there were no free channels in the media union on the 4th and 5th axes, which would have been necessary to operate a pneumatic or hydraulic clamping device. Retrofitting by the manufacturer was not an option due to delivery times and costs. MAFU-SHERPA impressed with a complete, single-source solution consisting of a SherpaLoader® M20 equipped with an electric torque wrench, along with an electric door drive and a robot interface for the processing machine. The existing clamping technology could be seamlessly integrated into the automation system, and proven machining parameters were retained, enabling a smooth transition to automation. Automation is viable for batch sizes starting at 10 parts. Thanks to the robust operation of the automation system, production runs of up to 50,000 parts per year can now be offered.

Within a year, the effective spindle time was increased from 6 to over 20 hours per day. For example, the automated system ran without any staff for many weekends. Schöbel is a perfect example of how even small companies can adopt robotics and thereby become serious competitors.

Johannes Seilbeck, Managing Director:

“Automation has more than doubled our revenue on the production line. That’s both a success and an incentive. That’s why we’ve just invested in a new processing machine from HERMLE—and in a second SherpaLoader. Now there are ten of us: eight people and two robots.”

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manufactures precision parts for the custom machine-building industry. The company is located in Gebesee, a town of 2,000 residents in the Thuringian Basin, where the shortage of skilled workers is particularly acute: In 2023, 49.5 percent of all open positions lacked qualified workers, and the forecast through 2035 does not look much better.

Owner Rene Liebl’s goal: To secure regional production in Gebesee by decoupling the job processing from staffing levels, so that short-notice jobs can be fulfilled regardless of staff availability.

Before automation

And even today, highly fluctuating demand remains at the heart of our day-to-day operations. A predictable order intake often does not reflect reality. Customers expect—especially for urgent requests—delivery within a few days or even right after the weekend. For requests with short lead times, there were none of the operators available for production during the late or night shifts.

The Solution

The solution consisted of a CNC automation system that continues to operate even after the operators have finished their shifts. The system was designed to load a MAZAK VCN-530C vertical machining center. The processing machine was retrofitted with a robot interface and two pneumatic clamping devices. The robot controller manages the clamping device, which minimized the cost of the retrofit. To further increase autonomous runtime, the SherpaLoader® was additionally equipped with a re-gripping station, allowing both the front and back sides to be machined in a single pass.

A SpaceBox serves as the material storage unit; it can hold over 400 blank parts measuring 60 x 100 x 35 mm, enabling an autonomous runtime of more than 60 hours.

Without any additional shift premiums, a robot now handles rush orders at night or mass production runs on weekends, ensuring that the parts are ready for shipment the next business day.

The workload on operators is reduced not only by eliminating night shifts, but also by simplifying order preparation. Today, the picking of raw material blanks is no longer performed by machine operators but by warehouse workers. Thanks to the decoupling of logistics and manufacturing, material preparation now takes place in the warehouse rather than in front of the machine tool, as was previously the case.

The secret to productivity lies not so much in speed as in the stability and continuity of processes. While an operator can work only one shift, a robot can work up to three shifts—without breaks and at a constant speed. For suitable jobs, the robot can be operated for more than 100 hours per week.

Rene Liebl, Owner:

“Qualified machine operators are hard to come by at the Gebesee site. That’s why we can only improve on-time delivery with the help of a robot. We simply can’t afford not to automate our CNC machines!”

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