Rethinking processes instead of isolated technology upgrades
The mid-sized company, employing around 450 people, has specialized for decades in complex, core-intensive castings for customers such as Caterpillar, Liebherr, and MAN. Despite this strong market position, the management faced key challenges: physically demanding manual tasks, a shortage of skilled workers, and rising quality requirements.
“It was clear that we had to fundamentally change something,” explains Mario Zimmer, Head of Finishing. “This was not about individual machines, but about completely rethinking our processes – from core production to finishing.”
The goal was a shift away from manual, stand-alone work toward fully automated process chains, raising productivity, occupational safety, and process stability to a new level while further reducing scrap.
Automation from the start: new core production system
The modernization began in core production. A new automated system significantly improved the efficiency and precision of core manufacturing and handling. It marks the starting point of a process chain in which all downstream steps are optimally synchronized in terms of output, quality, and cycle time.
Intelligent finishing: Reichmann MAUS 900 with CAAT software
At the heart of the new process landscape is the MAUS 900 CNC-controlled cleaning cell from Reichmann. It performs fully automated deburring and cleaning of all core-intensive castings, including complex cylinder heads.
Thanks to its high rigidity, laser monitoring, and integrated MAUS CAAT software, the system delivers maximum precision and repeatability. The CAAT software analyzes machining parameters in real time, continuously learns, and automatically adjusts cycle times – without any operator intervention.
“The CAAT software independently optimizes the program sequences. We can fully focus on the grinding results,” says Florian Herbst, responsible for technology and personnel in the finishing department.
Employees quickly embraced the new technology. After only a short training period, operators were able to run the system independently. The intuitive controls and significantly reduced physical strain led to high acceptance. Compared to previous manual work, physical workload was reduced by around 80%, while output increased by 120%.
Seamless automation: integration with the RUMP blasting system
After cleaning, surface treatment now takes place in a robot-guided RUMP blasting system that is directly linked to the MAUS 900. Together, these systems form the core of the new automated process line.
“The close integration of cleaning and blasting creates a highly efficient workflow,” emphasizes Mario Zimmer. “It not only saves time, but also significantly reduces scrap.”
Where manual blasting once involved heavy physical labor, robots now perform the task with precision and consistency – a major step toward ergonomic workplaces and sustainable process quality.
People as a success factor: planning, integration, and training
Reichmann supported the project end-to-end – from concept development and cycle time analysis to pre-acceptance tests and commissioning. Intensive employee training was an integral part of the approach, recognizing that technology alone delivers value only when people understand and support it.
Even after commissioning, Reichmann remains a reliable partner. Its customer service covers not only the new automation systems, but also ongoing support for existing MAUS machines, including spare parts, maintenance, training, and comprehensive service packages – ensuring long-term availability and expert support across the entire plant portfolio.
A showcase for the foundry of the future
Harz Guss Zorge demonstrates that automation is more than a technical investment – it is a cultural transformation. The combination of automated core production, the Reichmann MAUS 900, and the robot-guided RUMP blasting system has created a new process landscape that unites economic efficiency, quality assurance, and employee satisfaction.
This project stands as a prime example of how small and medium-sized foundries can secure their future: automation as an opportunity – not a replacement, but a strategic evolution.
