Heckler & Koch Uses Flexxbotics to Meet Growing Military & Defense Demand

The Problem

Increase capacity with precision quality

Heckler & Koch needed to increase capacity with precision quality to keep up with strong demand globally while addressing labor and skills challenges through unattended operation.

“Our main goals with digitalized automation are increasing throughput, maximizing machine utilization, and creating flexibility to react quickly to production volume demands which Flexxbotics enables us to achieve,” said John Mitchell, VP of Operations at HKUSA.

The Solution

Flexxbotics platform for autonomous process control

John Mitchell, VP of Operations at HKUSA continues, “From a business perspective we view Flexxbotics as an investment that enables autonomy in our factories.”

“With Flexxbotics, we achieve full ROI in less time without taking into account additional capacity than alternative solutions which exceeds our expectations,” explained John Mitchell, VP of Operations.

Heckler & Koch uses Flexxbotics to achieve robot-enabled, multi-machine cellularized setups for machining complex geometry parts. Flexxbotics coordinates both an Okuma 5-Axis vertical machining center and an Okuma horizontal machining center along with an integrated water dunk & blow-off station, a Hexagon Coordinate Measuring Machine (CMM), Renishaw inspection probe and SICK safety scanner in cellularized configurations. Automating the complete process of machining and inspection results in an 87% capacity increase and 24:1 machine-to-man ratio.

“Flexxbotics’s ability to coordinate multiple machines and have in-line inspection results automatically correct the machining operations using approved adjustments is totally unique and was key for us,” said John Mitchell, VP of Operations at HKUSA.

The Flexxbotics solution seamlessly connects the automation to each piece of equipment and coordinates workcell equipment and robotic automation. Using closed-loop feedback from CMM inspection results, Flexxbotics writes offset macro variable changes to the CNC machines’ programs. The real time corrections ensure all parts are built to spec for continuous operations using autonomous process control.

In addition, Flexxbotics communicates with the in-machine probes to ensure proper part seating before and after each CNC cycle. Based on the probe’s feedback, the robot either automatically remove and replace the part or escalates the problem via text & email if there is a workholding issue.

• Increased production capacity by 87% and achieved a 24:1 machine-to-man ratio.
• Open connectivity and interoperability between the robots, CNC machines and inspection equipment.
• In-line inspection with CMM for precision quality, 100% part coverage, and closed-loop optimization for uninterrupted production.
• Integrated safety with robot+machine coordination and connected safety scanners for the highest levels of human safety.
• Solution flexibility to scale out with success and quickly adapt.