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Smart Factory Stoppani

Dual Factory Two Factories under One Roof

Stoppani Metal Systems

Stoppani Metal Systems

The Swiss contract manufacturer SwissFactory.Group has introduced new structures and, in particular, significantly modernized the sheet metal processing division of its subsidiary Stoppani Metal Systems. Now the implementation of a “dual factory” is sought, where people work during the day and machines work at night. This digital factory is to run production fully automatically and autonomously, guaranteeing international competitiveness for Stoppani. Bystronic was the only provider able to meet these requirements.

Stoppani Smart Factory

Background

From engineering to series production: outsourcing solutions from a single source. Supported by over 220 employees, Stoppani Metal Systems in the Bern region of Switzerland covers the entire value chain in contract manufacturing and assembly.

Challenges

For Stoppani’s production in Switzerland to be competitive for customers, it is essential that it is operated fully automatically. The goal was to completely digitalize planning, storage, intralogistics, tool changing, production, and quality control to reduce costs by approximately 35 percent.

Solutions

Integrating bending and cutting cells with the warehouse, Bystronic designed fully automatic, digital production. Furthermore, existing and new machines from other suppliers could be additionally integrated fully automatically into the complete solution. This allowed Stoppani to make great progress toward a “dual factory.”

Seizing the opportunities of Industry 4.0: Hans Gattlen, co-owner and Chairman of Stoppani.

“Under a single roof, we have two factories: a human factory and a digital one.”

Hans Gattlen, co-owner and Chairman of Stoppani’s Board of Directors

Bystronic Solution

Bystronic solution

From the vision to the Smart Factory: Fully automated production processes are necessary in order for manufacturing at the Swiss location to be competitive. They enable increased efficiency and productivity and
ensure profitability.

Project Plan Smart Factory Stoppani

Bystronic machines: 1× bending cell with an Xpert Pro 150/3100, Xpert 40 & Xpert 80 with a Mobile Bending Robot each, 1× ByStar Fiber 3015 6kW, 1× ByTrans Cross with BySort and sheet storage, 2× integration with machines from other suppliers

Project Plan Smart Factory Stoppani

Bystronic machines: 1× bending cell with an Xpert Pro 150/3100, Xpert 40 & Xpert 80 with a Mobile Bending Robot each, 1× ByStar Fiber 3015 6kW, 1× ByTrans Cross with BySort and sheet storage, 2× integration with machines from other suppliers

Solution Project Implementation

Solution project implementation

Preparation

Collaboratively, a material and data flow was developed to meet Stoppani’s requirements. Based on this, existing production was expanded into additional production halls. Stoppani can now consider incorporating further process steps into the Smart Factory with automation.

Implementation

From the vision to implementation: Storage was designed such that modular expansion will be possible in later stages. A customer-specific layout for the bending cell was worked out to enable a warehouse connection. The idea of the “dual factory” can thus be pursued further, and the next stages of expansion can be undertaken.

Go-live

One challenge was in designing and commissioning one of the first bending cells according to customer specifications and on schedule. In parallel, machines from Bystronic and other suppliers were integrated fully automatically into the complete solution. The project steps could be successfully implemented thanks to close collaboration.