In recent times, automotive manufacturers are more focused on manufacturing lightweight automobiles without affecting durability of the vehicles. Therefore, die casting is one of the most valuable techniques adopted by the manufacturers for creating automotive parts. The number of die cast parts used for automobiles continues to rise daily. Some of the main reasons for the increase in demand of die casting by the manufactures are:

Increased precision, efficiency and cost effectiveness

Die casting is a technology that helps in increasing precision, efficiency and cost effectiveness of the automobiles / vehicles that are getting manufactured by using die casted products or components. Die casting is also one of main reason behind numerous automotive advancements that are witnessed by all of us. With the ability to mold materials such as zinc, aluminum and magnesium alloys, die casting unlocks various other opportunities that helps in elevating vehicle performance boosting in an overall growth of automotive industry.

Helps in fuel efficiency

The inclusion of die cast components in the automobiles, mainly in engines, also helps in fuel efficiency as the overall weight of the vehicle reduces when die casted components are used which also results in lower emissions resulting in reduction of pollution and better vehicle performance that helps in production of more units effectively and efficiently.

Increased automation and flexibility

The popularity of automotive die casting is increasing day by day all over the globe due to the high use of advanced technology in almost every industry. All the process becomes more effective and productive when the production process is automated. Moreover, die casting technique helps to create parts with complex shapes and sizes easily which ultimately makes the installation process smoother.

As discussed above, die casting helps to produce parts with complex shapes with high durability and improved aesthetic appearances. Following are some of the parts / systems from wide variety of applications of die casting for automobiles that includes:

• Engine parts
• Mounting brackets for electric motors and stepper motors
• Electronic covers for gearbox
• Sensor and airbag housings as active safety mechanisms
• Fuel intake parts
• Air conditioning systems
• Mounting brackets for stepper motors
• Retractor spools for seatbelts
• Transmission components
• Sensors
• Chassis components
• Durable power steering and braking systems

Advancements in die casting technology

As automotive manufacturers strive to stay at the top of innovation and adapt to new technologies, die casting technology has evolved to meet the growing demands of the industry which also helps the manufacturers to product the vehicles with the new technology that also helps in customer satisfaction. Some of the main advanced die casting techniques are playing a crucial role in achieving higher levels of precision and efficiency in automotive industry such as:

1. High pressure die casting

High pressure die casting involves injecting molten metal into a steel mold at high pressures that results in faster cycle times and enhanced part integrity of the vehicles. This type of die casting technology helps in the production of complex automotive components with minimal porosity, ensuring the highest quality and durability.

2. Vacuum die casting

In vacuum die casting, the process is carried out in a controlled environment with reduced air pressure. This method minimizes gas porosity in the final product that is being produced, further also improving the structural integrity of the automotive components. In recent times, manufacturers are increasingly adopting to vacuum die casting for manufacturing the critical parts, such as engine components and safety mechanisms.

Innovations in die casting materials

With the aim to create light weight yet robust automotive components, die casting industry has witnessed continuous material innovations. The incorporation of advanced alloys, such as zinc – aluminum alloys, has become prevalent. These alloys not only offer improved strength and durability to the vehicles but also provide a higher degree of corrosion resistance to them. The composition of the materials can also be customised as per the requirements which results in enhancing the overall performance of die – cast automotive parts.

This customization capability not only focuses on specific performance requirements but also opens various opportunities to include die casting materials for diverse applications in manufacturing other different components for automobiles. As a result, the evolution of die casting materials is not just about meeting the current industry needs but also about anticipating and adapting to future technologies and challenges in the automotive manufacturing industry.

Sustainable practices in die casting

In response to growing environmental concerns among the individuals and manufacturers, the automotive industry along with various other industries is also increasingly focusing on sustainable practices for most of the processes. Die casting foundries are also collaborating with many automotive manufacturers to implement eco – friendly measures in their production and all other operations. This includes the use of energy – efficient equipments, recycling of process water and the implementation of green manufacturing practices. This aligns with the automotive industry’s commitment to reducing its carbon footprint.
By aligning the die casting processes with sustainability goals, the automotive industry is moving towards a more environmentally responsible approach that will not only help the environment but will also help the companies in the long run.

Future opportunities

In the ever – evolving industry of die casting, several new and trending opportunities are emerging which is helping to push the industry towards enhanced capabilities and efficiency. Let us have a look at some of the possible future opportunities that lies there for die casting industry with respect to automotive industry.

New materials and alloys

Research into new materials and alloys is opening opportunities for enhanced die casting capabilities. Materials with improved strength and durability are being explored to meet the evolving needs of the automotive industry that will help in the manufacturing of different types of parts and components for automobiles that will be having more stability and resistance to make the final product much better from now.

Smart manufacturing and industry 4.0

The integration of smart technologies and industry 4.0 principles enables real – time monitoring and control of die casting processes. Predictive maintenance, data analytics, estimation of demand – supply and automation contribute to increased efficiency and reduced downtime which helps in the overall growth of the manufacturers as well as of the automotive industry.

3D printing and prototyping

The unification of 3D printing technologies in die casting processes allows for rapid prototyping and the creation of complex geometries that are required in day-to-day basis in automotive industry. This innovation accelerates the product development cycle of the parts and components that are manufactured and supports the customization of automotive components.

Collaborative research and development

Collaboration between die casting manufacturers, automotive companies, and research institutions fosters a scope for continuous improvement. Shared knowledge and expertise can lead to breakthroughs in die casting technology that can also help in analysing the challenges that are faced in the correct manner and take corrective actions and measure to tackle them.

Conclusion

In conclusion, the innovation and efficiency in automotive industry has led to the widespread adoption of die casting techniques, particularly in the manufacturing of light weight and durable components. Die casting not only enhances precision, efficiency, and cost – effectiveness but also contributes to fuel efficiency, automation and flexibility in the production processes that are done for the production of parts and components of automobiles. The diverse applications of die casting in creating complex parts for engines, safety mechanisms and various automotive systems throws light on its pivotal role in shaping the future of the automotive sector with the help of die casting in the process.

The evolution of die casting technology, including high – pressure die casting and vacuum die casting, showcases the industry’s commitment to achieving higher levels of precision during the process of production. Material innovations for die casting are also resulting in contributing to create robust and lightweight automotive components. Moreover, the industry’s increasing focus on sustainable practices focuses on environmental concerns emphasizing a responsible approach towards reducing the carbon footprint.

Looking forward, the automotive industry anticipates exciting opportunities in the near future, including the exploration of new materials and alloys, the integration of smart manufacturing and industry 4.0 principles, the adoption of 3D printing for prototyping and collaborative research and development initiatives. The points mentioned above not only promises improved and enhanced die casting capabilities but also signifies a collective effort towards continuous improvement.

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The term automation defines the introduction in a manufacturing company of technical tools and processes aimed at reducing or even eliminating human operations. Indeed, the most relevant benefit of automation is the reduction of workload for the operators, which consequently leads to additional advantages such as reduced lead time, costs reduction and achievement of quality standards requested by clients. Automation can therefore contribute to production process improvement, enhancing accuracy, precision, productivity, robustness and consistency of outputs.

CASE STUDY

In Bruschi we are always seeking for innovative solutions that can help improving the productive process. In order to fulfill this aim, the production department has developed a project for reducing operators’ workload with the introduction of automation. This project concerned two specific components produced for a client of the sector of small appliances and has obtained excellent results in terms of reduction of manual activities of operators and increased productivity.
In order to define the two components to optimize among those available, engineers have conducted an analysis with the support of the Pareto chart, which has led to the following results:

• 20% output produced by 0,05% of components
• 60% output produced by 17% of components
• 20% output produced by 82,95% of components

Results show that 0,05% of components generates 20% of the output produced by the company: these components are known as runner products. The presence of few components that generate such a substantial output allow the introduction in the production department of a specific automation without reducing productive flexibility of the company.

Definition of project’s phases

After having selected the components, the different stages of the project can be defined. The iterative improvement process is indeed divided in four phases, with reference to PDCA cycle or Deming cycle:

• Phase 1 – PLAN
Definition of the problem, identification of the causes and hypothesis of corrective actions to reach expected objectives.

• Phase 2 – DO
Implementing corrective actions defined in phase 1.

• Phase 3 – CHECK
Collecting and checking data. Comparison between expected results and observed results.

• Phase 4 – ACT
Implementing corrective actions emerged from data analysis of phase 3.

The four phases of PDCA cycle have been planned using the following Gantt chart:

Phase 1 – PLAN

The first phase starts with the definition of the problem: a condition of misalignment between production capacity and client’s request, with hypothesis of producing both the components on the same die casting machine due to plant saturation. Therefore, the problem can not be solved producing the two components on two different die casting machines: it is in fact necessary to improve the production process of the components.
The identification of the root cause involves the study and the definition of the average duration of single activities, manual and automatic ones:

• Die casting – automated operation managed by the machine
• Pick up and lay down of the piece – automated operation managed by anthropomorphic robot
• Degating and reprocessing – manual operation managed by the operator
• Auxiliary activities – manual operation managed by the operator

Once average duration of every single activity has been calculated, improvement focuses on activities that can generate more benefits, so the ones that take up the most of the time of the operator. Manual activities that have been selected are reprocessing, raw-scrap division and die casting machine fueling: these activities take up 97% of the operator’s time.

The second step concerns the classification of operations on the basis of the added value they generate for the customer:

• VA = 0 % – Necessary Value Added activities: known, therefore paid by the client
• NVA = 3 % – Unnecessary Non-Value Added activities: unknown, therefore not paid by the client
• NNVA = 97% – Necessary Non-Value Added activities: unknown, therefore not paid by the client

First of all it is essential to work on NVA activities, in order to understand how to eliminate them. Secondly, NNVA must be analyzed and improved. Normally, VA activities can be improved but with little margin.

Phase 2 – DO

Phase 2 involves a cost-benefit analysis in order to identify the best solution between externalization and self-improvement through automation. Both the alternatives have been implemented:
• externalization of manual activities equal to 50%
• reduction of manual activities equal to 45%, through introduction of automation that operates automatic division of the pieces from the sprue runners and automatic recasting of the sprue runners

Phase 3 – CHECK

The third phase of the project involved collecting and checking data, with comparison between expected results and obtained results. Observation period after improvement actions have been implemented was of 240 working hours. Three numerical KPI (Key Performance Indicators) have been considered in order to evaluate the efficacy of improvement action:

1. OEE (Overall Equipment Effectiveness)
2. Average duration of manual activities
3. Tons of zamak recasted in the machine spot

The comparison of these indicators before and after improvement actions has highlighted +33% OEE and -95% manual activities, with a complete recasting of scrap material.

Phase 4 – ACT

Phase 4 has not concerned any action because after KPI analysis no anomalies were observed.

ACHIEVED BENEFITS

The project has led to several benefits for the production department, both direct and indirect ones.

Direct benefits:
• +33% OEE
• -95% manual activities
• Complete scrap recasting in the machine spot

Indirect benefits:
• Increase of client’s satisfaction. Met and reduced lead time thanks to productive capacity increase, improvement of superficial quality of the component and stabilization of degating and reworking processes
• Energy saving associated with immediate casting of raw material
• Reduction of waste due to handling associated with elimination of scrap transfer

This case study demonstrates the importance of automation in a productive system that is efficient and technologically advanced: through the introduction of automated systems it was indeed possible to meet qualitative and quantitative standards demanded by the client, meeting the requested deadline at the same time.

If you are interested in production process improvement, here are additional posts:
• Production process improvement in the die casting industry
• Casting process optimization: design of hot chamber injection system

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Productivity enhancement represents, indeed, an advantage both for the supplier and the client: on the one hand the supplier benefits from costs savings, while on the other hand the client can rely on a partner that offers quality performances in short times. Bruschi has always considered this subject a core aspect, as a matter of fact through the years Bruschi has taken several measures in order to achieve an ever-increasing process improvement.

How to reach process improvement

Process improvement can be developed through a well-defined action plan, which takes into consideration the complexity of elements that characterizes the production department. Production is indeed composed not only of machinery, but also of product design, technologies, operators and planning activities, to mention some of the most important components of this structured system. To improve the production process it is therefore crucial to have a comprehensive view of all these elements, in order to implement a strategy that is functional on multiple aspects.

As a consequence, the first step to take is the setting of the tools and of the adjustment actions that can impact on the improvement of the different stages of the production. In Bruschi the process improvement plan is composed of four central elements:

1. Automation

2. Simulation

3. Scrap reduction

4. Cycle time

1. Automation

The introduction in a production system of automated machinery equipped with state-of-the-art technologies generates relevant benefits in terms of reduced lead time, costs reduction and achievement of quality standards requested by clients. The replacement of workforce with automated systems allows, indeed, to obtain a faster process, consequently enhancing the whole lead time. In addition to that, automation leads to a reduced likelihood of error compared to manual operations. This translates into a relevant production costs reduction, which is further increased thanks to energy and material saving that automation generates. The introduction of automated machinery in the production department produces another significant advantage that allows quality control improvement, too. As a matter of fact, operators that previously dealt with manual operations on the component thanks to automation can take responsibility for other activities with a higher added-value, such as quality control.

A process improvement project of a specific component, for a client of the sector of small appliances, has obtained excellent results in terms of increased productivity and decrease of manual activities of operators. Process improvement project has been developed in order to solve a situation of misalignment between production capacity and client’s demand. Through the introduction of automated systems this gap has been narrowed, thus achieving an optimized cycle time. After several studies and researches it has been possible to apply some changes to the process, which have brought to significant benefits: an increase of 33% of production capacity and a decrease of -95% of manual activities made by operators.

For more detailed information on automation consult the post below:

• How automation helps improving the production process
• The Importance Of Automation Optimize The Production Time

2. Simulation

Simulation of the die casting process represents another essential element that impacts on process improvement: with simulation software engineers can indeed foresee material reactions inside the mold. This process is feasible thanks to a thermos-fluid dynamic analysis of the mold, known as CFD simulation (Computational Fluid Dynamics), which allows the engineer to detect potential defects, such as cold laps and hot spots, on the die cast. The simulation stage proves especially helpful to obtain an optimized mold design before starting with the production process. During this stage it is indeed possible to select the best mold design parameters to apply, so that potential defects on the piece are previously detected and, consequently, production costs and further mechanical operations are reduced.

If you are interested in simulation, here are additional posts on this topic:

• The Benefits Of Simulation In Die Casting Design
• Die Casting Simulation For Shrinkage Porosity Prediction
• How To Use Die Casting Simulation For Cost Reduction
• Hpdc Simulation For Die Casting Process Optimization
• Die Casting Simulation A Casting Process Optimization
• Hpdc Simulation Benefits For Die Casting
• Simulation For Hpdc Surface Aesthetical Quality In Automotive Case Study
• Simulation For Hpdc Shrinkage Porosity Case Study
• Simulation For Hpdc Die Maintenance And Optimization Of Set Up

3. Scrap reduction

Scrap reduction can be achieved through an accurate planning of the whole production process of a component. First of all it is necessary to carry out a product and process analysis that focuses on the causes of scrap. To identify these causes engineers must use simulation software to foresee every stage of the production, from design to finishing operations. Once again simulation proves to be an indispensable tool for zinc die casting process improvement, because it allows engineers to avoid defects and to check technical properties before starting with the component production, thus producing a consistent costs and lead time reduction. Once scrap causes have been figured out it is possible to proceed to the outlining of potential solutions to apply, identifying the most relevant steps in the production process and constantly checking them.

To know more about scrap reduction, here are extra posts on the topic:

• How To Reduce Scrap In Die Casting Process
• Simulation For HPDC Scrap Reduction Case Study

4. Cycle time

The expression cycle time defines the period of time required to produce a product. Cycle time represents a central variable in the production of a component because a reduced cycle time results in a reduced lead time, which is the period of time needed to accomplish a customer’s request in terms of supply. An optimized lead time generates an increase in the client’s satisfaction, because it allows the supplier to meet deadlines and standards demanded by the client. As a consequence, in order to guarantee a rapid and efficient service, cycle and lead time have to be enhanced to the maximum extent possible. Cycle time can be shortened paying attention to different aspects of the production process, especially to simulation stage and to technological systems of the production department. First of all, as already mentioned, it is important to simulate production and defining the best process parameters to apply for the production process. In this way potential defects will be avoided from the very beginning and, consequently, it will be possible to eliminate further mechanical operations. Another core element for cycle time shortening is the technological system of the foundry, whose technological innovation level can generate relevant time reduction during the production process. As a matter of fact, automated machines lead to optimized cycle times and to more accurate operations, discriminating factors for the achieving of performances requested by customers. Furthermore, periodical checks on machinery help understanding how cycle time can be further improved.

Check the posts below to learn more about cycle time:

• Process Optimization For Die Casting Cycle Time Reduction
• How Die Casting Cycle Time Optimization Can Help To Reduce Costs

Why process improvement is crucial for a business

Process improvement is a crucial element in the management of a business because it leads to production costs reduction and faster productive processes. With the aim of reaching these benefits it is therefore necessary to introduce automated technology and simulation software in the production process, and to optimize scrap reduction and cycle time. With the outlining of a precise process improvement plan lead time can be shortened and, as a result, client’s satisfaction will be increased.

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THE STANDARD CYCLE

The term “die casting cycle time” is used to identify the time lapse between the beginning of an injection cycle and the next one. It can be obtained through a summation of the partial times in the die casting process. The standard cycle can be divided in the following phases:

• Injection time:

The piston follows a defined route at 1^st phase speed, through which the material is pushed up to the nozzle; it will then be accelerated by a nitrogen expansion in the accumulator in order to reach 2^nd phase speed, leading to the filling of the mold cavity.

• Die casting technical time:

It includes both compacting and cooling phases, thus involving metal change of state, from molten to solid. A compacting phase is necessary to compensate the volume reduction caused by phase transection.

• Mold shifting/lubrication time:

It is the sum of mold opening and closing time, extractor’s forward and backward movements and mold lubrication time. The lubrication can be manual, done with a Cartesian system or  with fixed nozzles.

• Control time (optional):

It can vary depending on the piece-release system of choice. When the withdrawal is done by a robot, it would be advisable to choose a control system based on photocells. In a free-fall on balance system it will be necessary to set the expected weight on the scale, in order to detect eventual missing parts that could be left inside the mold.

At the end of the die casting cycle, further operations of runners and overflow removal are needed and, for some critical products, further refinishing. Some of these operations can be executed manually by a worker, while others -such as threading- require a dispatching of the raw piece to third-part firms.

Alternatively, it is possible to integrate the production line with anautomated system in line with the casting machine. By using automated machines for scrap removal it is possible to save man-hours, which can be invested in different ways, for example in Kaizen activities.

Another viable optimization can be achieved by integrating automations in the die casting machine for precise machining, such as threading, thus reducing WIP’s transit time in the plant. Thanks to this integrated automatic machineries, capable of complex machining, it is possible to reduce lead time and to fulfill client’s request more easily.

The time necessary to complete the whole automation cycle adds (or overlaps) to die casting cycle time, and together they form the standard cycle time for a determined product.

HOW TO MEASURE COMPANY PERFORMANCES

In order to quantify a company performances, it is possible to rely on 2 indexes:

• The first one is OEE (Overall Equipment Effectiveness), a percentage measure obtained by multiplying availability, performance and quality. The index refers to the productive return of the plant;
• The second one is OTIF (On time in Full), which expresses as a percentage the logistic ability of a company to send the requested quantity of products at the expected time and place;

The optimization of cycle time increases the OEE value by rising the efficiency. Moreover, thanks to a systematic reduction of production time, more machine-hours are available, allowing the company to fulfill a bigger number of orders without changing the plant opening hours.

As stated above, OEE is composed of 3 factors:

• Availability: the relation between available machine time and operating machine time;
• Performance: the relation between produced pieces and producible pieces;
• Quality: the relation between pieces and produced pieces;

Frequently the improvement in die casting cycle time also affects the quality of the casting. A time reduction implies an increased number of injection per hour, which intensifies mold thermal input produced by the molten metal. This leads to an improvement in the surface quality of the casting, since it decreases the number of cold fronts responsible for cold laps on the surface.

There are many advantages achievable by an effective cycle time optimization, that can enhance the whole production. In the next paragraph we are going to explain in detail some techniques for time cycle improvement.

HOW TO OPTIMIZE DIE CASTING AND AUTOMATION CYCLE TIME

First of all, it is necessary to define whether to intervene on the die casting cycle or on the automation cycle. In an ideal production cycle the two coincide, which means that the process are all parallelized and there are no bottlenecks.

In order to define the priority of an intervention a Pareto chart of partial times can be used: the chart is composed of an histogram representing the distribution rate of a phenomenon, displayed in decreasing order so as to permit instantaneous identification of the main factors. After a graph analysis it will be possible to spot the critical points in need of optimization: we are going to choose the highest impact elements.

Once the graph is defined, we need to proceed with a separation between independent processing time and dependent processing time.

The term “independent processing time” is used to define actions that occur in series, one after the other. The reduction of an independent processing time entails an immediate reduction of the cycle time.

On the contrary, dependent processing time define those operations that occurs at the same time as a different one; the reduction of a dependent processing time without a reduction of the main process from which it depends, does not create a variation in the cycle time.

• Revising independent processing time: automation with robotic withdrawal

Once decided to reduce automation time, the next step will be to film the whole cycle of the robot, from withdrawal to dump. Thanks to this shooting, it will be possible to write a complete list of the robot’s movements and operations, along with their exact duration. Starting from these data, it will be defined whether to intervene on the movement speed or on their trajectory.

The movements done by a withdrawal robot through the course of a working cycle are: aligning with the machine columns, entering the press area, withdrawal of the diecasted product, exiting from the press area, transit to the check point and dump.

Before proceeding to the actual optimization, some simulations are run in order to form die casting cycle time hypothesis, and afterwards decide how to intervene: sometimes it is sufficient to alter  speed of movement, some others it will be necessary to remove superfluous movements.

•  Optimization of die casting time

Die casting process optimization is more challenging, since the majority of the process requires a fixed amount of time, for example in operations like piston compression and casting cooling. Examples of possible improvements in this phase are:

• Cooling time
  It can be reduced modifying the mold’s thermoregulation through the use of water/oil cooling units; in other words, a reduction of waiting time of the cast in the mold can be compensated by a reduction of T° in the thermoregulation fluid.
• Die casting duration
  A prefilling function can be a useful support, since the saving per cycle can be assimilated by the duration of the first phase of injection. The movement of the piston in the 1^st phase is then transformed from independent time to a dependent time, bounded to mold closing.

For a better chance of optimization it is possible to intervene on the extraction time (start delay, course speed, return speed, return delay, number of runs), mold opening/closing (opening/closing speed, aperture run) and lubrication (start delay, duration).

When working with an automation system, the necessity of synchronizing movements of the robot to the new schedule should be taken in account. The optimization of cycle time can be highly variable and bring to a 20-30% time reduction or greater, thus leading to a good economical saving for the company.

To learn more about production cycle time optimization, please take a look at our other posts on the topic.

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The most relevant benefit of automation is the reduction of workload for the operators, but it proves also beneficial in terms of energy and materials savings.  Automation can therefore lead to production process improvement, enhancing accuracy, precision, productivity, robustness, consistency of outputs and quality.

Automation can be implemented through different tools, such as mechanical, hydraulic, pneumatic, electrical, electronic devices and computers, usually used together.

Automation in Bruschi

Bruschi has introduced automatic systems in its foundry to improve production time during the production process. Several operations that are carried out by workmen can be replaced with automation.

Since its establishment Bruschi has always been innovative in terms of automation, but in 2011 this concept has been widen with important investments.

Indeed, in 2011 automation was implemented with new robots ABB with IRC5 control: controls that are the productive unit of governance of the robot. In this way it is possible to use remote assistance to have access to all the functions of the robot to control and maintain it.

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Bruschi previously had an outdated system that needed to be improved and innovated. Consequently, Bruschi decided to create a new installation: the management purchased a cooling tower and created around it a complex system: a project was outlined, pumps and water tanks were built and the cooling tower was finally activated in order to save time and energy. Once the operator decides to create a program, he will need a PLC that is possible to set up with incomes and outcomes depending on the aims. This program has a lot of advantages, but the most important is to email the responsible during breakdown. In this way the operator can solve the problem promptly.

Simulation in Bruschi is really important because with this tool it is possibile to examine the mold before the production process starts and to simulate what the organization of the production will be.

This software is made by ABB company and with it it is possible to do the pre-installation operations: try it in preview, decide if something has to be modified, reduce installation and set up time using offline technology, it is possible to do it in the office instead of directly in the field.

Between 2016 and 2017 Bruschi has purchased three new robots. The idea is to use a new control system with better performances than the one already used in Bruschi.

Everything is possible thanks to qualified people and a large amount of investment that Bruschi does in terms of automation and robotics.

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