A walkthrough of AKV Metallbau’s digital production
Managing Director Sebastian Busch takes you through his digitalised factory. He explains each workstation and shows, using real examples, how Logikal MES has streamlined production.
AKV Metallbau
The company, based in Mannheim, was founded in 1978. Its focus is the manufacture of windows, doors and façades made from glass and aluminium, with plastic and steel also processed.
AKV Metallbau has used Logikal for design and costing since 2004. In 2018, Managing Director Sebastian Busch extended these processes into production with Logikal MES, creating a consistent digital workflow.
From Logikal straight to the workshop
AKV Metallbau designs in Logikal and defines all components, fittings and machining steps within the software.
“When the design is completed in Logikal, we simply perform a global export instead of exporting each individual machine file and printing documents such as cutting lists and job orders,” explains Sebastian Busch. “Everything is done with a single click.” Selected positions are exported in one step, automatically generating all machine data and the export for Logikal MES.
“When the design is completed in Logikal, we simply perform a global export instead of exporting each individual machine file and printing documents such as cutting lists and job orders. Everything is done with a single click.”
- Sebastian Busch, Managing Director, AKV Metallbau GmbH
Full visibility of the entire project
For Sebastian Busch, the key advantage of digital production with Logikal MES is transparency and control:
“The advantage of Logikal MES is that, in addition to the traditional machine data, we also have an overall view of the project.” He demonstrates this using his CAM system and the MES terminal above it. The second screen displays additional project data. “You can search through the individual profiles, filter by profile numbers or projects, and easily select the bar to be processed,” he shows.
Logikal MES also displays profile length, shows the cross-section and assigns a rack location. This ensures that staff immediately know where each profile needs to be stored.
Drilling, milling, countersinking – fully automated
Using his 5-axis machining centre as an example, Busch explains: “All profiles to be machined are automatically routed by the system to the work station of the machining center.” Machining is carried out along the full length of the bar. A six-metre profile is loaded, and the clamps position themselves automatically. “All drilling, milling, countersinking, threading, cutting, and trimming operations are performed fully automatically, one after the other. No manual intervention is required during the process,” he explains. “This allows the employee to prepare the next profiles or continue with assembly work, rather than being tied to a single workstation, making waiting times more productive and cost-efficient.”
Direct link to the shopfloor manager
Logikal MES automatically pre-sorts tasks and assigns them to the machining centre, the saw or directly to assembly. Information is available at the right place at the right time. At the saw, glazing beads, clamping shells and cover caps are processed. The MES terminal shows all profiles in a side list. The operator opens the cutting file and works through it step by step. No profile is overlooked. In-house production checks can be integrated directly. “If a minor defect is detected on a profile, the employee can record it directly in the system,” explains Busch. The workshop manager has full visibility. They can immediately see if a profile needs to be reordered or requires rework or inspection.
Work orders? Fully digital!
As soon as all bars and profiles for an element are complete, the transport rack is released and becomes visible to the next workstation, such as frame assembly. Operators access all assembly information directly via the terminal. “We no longer use paper work orders,” says Busch.
Manufacturer processing guidelines are also integrated into Logikal MES via interfaces. “Direct links to suppliers are available, allowing users to access the supplier’s online catalog with a single click on an article number.” For assembly, AKV Metallbau uses a second large-format screen. The first screen shows detailed data, while the second displays drawings at scale. “This allows all information to be viewed at full scale,” explains Busch. This replaces DIN A0 and A1 printouts and ensures that the latest drawings are always available at the workstation.
"We no longer use paper work orders.“
- Sebastian Busch, Managing Director, AKV Metallbau GmbH
Individually configured MES layout
Before switching to digital production, the MES system is carefully set up. This is done in close collaboration with Logikal MES experts. All processes are mapped in the system, ensuring smooth operations and enabling the software to deliver its full value.
AKV Metallbau benefits from this setup every day with an efficient, paperless workflow.
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