CIE LT Forge is a modern metalworking company based in Marijampolė, Lithuania Founded in 1996 the company specializes in the production of automotive components that require specialized manufacturing processes and high-quality machining. The main production processes include hot and warm forging, as well as thermal and precision mechanical processing enabling the delivery of fully finished products to clients. In 2023 the company reported sales revenue of €55,7 million and a net profit of €6,6 million. Currently CIE LT FORGE employs 224 staff members, with an average salary of €2,672,63. The company prides itself on managing high value added processes and maintaining consistent growth in the metalworking sector.
Task. The purpose of the project was not only to increase production efficiency but also to improve product quality, allowing a single operator to control the entire line. The project involved upgrading existing equipment components (press, lubrication, cooling, and other systems) and integrating new technologies, including robots. It was important to ensure that the new system would be flexible and allow for easy implementation of additional robotic functions in the future, such as trimming press automation.
Initial state. Before automation, the line consisted of a complex of several machines: an induction furnace, mechanical billet conveyors, a forging press, and a trimming press. The work was performed manually by two operators.
Automation process. During automation, three KUKA “Foundry” series robots, specially designed to work in harsh environments, were installed. They were integrated with various grippers and sensors, ensuring precise and fast billet handling. The system was complemented with new billet feeding, forging cooling, and extraction conveyors, which were designed to minimize operational disruptions and ensure continuous production processes.
A new SCADA system for full production line management was developed, integrating the controllers of the presses, robots, furnace, and other systems into a central control panel. The system was designed to operate non-stop, 24/7.
Project results. The new automated system was successfully integrated into the production processes, significantly increasing productivity and reducing quality deviations. Automation enabled the optimization of labor costs and reduced potential workplace accidents, ensuring a higher level of production safety.
Forging line equipment:
- 2x KUKA KR 70 R2500 Foundry robots
- 1x KUKA KR 120 R3200 Foundry robot
- Techvitas Robotika mechanical billet grippers
- Techvitas Robotika billet feeding, extraction, and unloading conveyor system
- Techvitas Robotika product cooling system
- New automation cabinets
- SICK safety light curtains and locks
- TROAX safety fences
- SIEMENS programmable logic controller (PLC)
- SIEMENS central control system panel (SCADA)
- Metal billet temperature: 850°C – 1250°C
- Metal billet weight up to 15 kg
- Minimum billet diameter 30mm
- Maximum billet diameter 90 mm
- Billet temperature : 850°C – 1250°C
- Cycle time approximately 6s
- System ambient temperature from +15°C iki +45°C
PHOTO GALLERY
- All projects
- Palletizing
- MACHINE LOADING AND UNLOADING
- DEPALLETIZING
- OTHER SOLUTIONS
- PACKAGING
