Harz Guss Zorge is setting new standards in foundry work: 120 per cent more output with 80 per cent less physical strain – thanks to intelligent automation with Reichmann and RUMP
Rethinking processes rather than using technology in isolation
The medium-sized company, with around 450 employees, has specialised for decades in complex, core-intensive castings, including for Caterpillar, Liebherr and MAN. Despite this strong market position, the company faced key challenges: physically demanding work, a growing shortage of skilled workers and rising quality requirements.
“It was clear to us that we needed to make fundamental changes,” explains Mario Zimmer, Head of the Desmoulding Department. “It wasn’t about individual machines, but about a complete rethink of the processes – from core production right through to finishing.”
The aim was to move away from manual, individual tasks towards end-to-end, automated workflows in order to significantly increase productivity, occupational safety and process stability, whilst further reducing scrap.
Automation from the outset: new system in core production
The modernisation process began in core production. A new, automated system was installed there, making the production and handling of cores significantly more efficient and precise. It marks the start of a process chain in which all downstream steps are optimally coordinated – in terms of cycle time, quality and output.
Intelligent post-processing: Reichmann MAUS 900 with CAAT software
At the heart of the new process landscape is the CNC-controlled MAUS 900 cleaning cell from Reichmann. It handles the automated deburring and cleaning of all core-intensive castings, including complex cylinder heads.
Thanks to high rigidity, laser monitoring and the integrated MAUS CAAT software, the highest levels of precision and repeatability are achieved. The software analyses machining parameters in real time, continuously learns and automatically adjusts cycle times – entirely without any intervention from the operating staff.
“The CAAT software optimises the programmes autonomously. We can concentrate fully on the grinding result,” explains Florian Herbst, who is responsible for technology and personnel in the grinding shop.
The staff have also quickly embraced the new technology. After a short training period, they were able to operate the system independently. The intuitive operation and the significantly reduced physical strain have ensured a high level of acceptance. Overall, physical strain has fallen by around 80%, whilst output has increased by 120%.
End-to-end automation: integration with the RUMP blasting system
Following cleaning, surface treatment takes place in a robot-assisted blasting system from RUMP, which is directly linked to the MAUS 900. Together, both systems form the backbone of the new production line.
“The close integration of cleaning and blasting creates a highly efficient process,” emphasises Mario Zimmer. “This saves time and significantly reduces scrap.”
Where heavy manual blasting work was previously required, robots now carry out these tasks with precision and reproducibility – a significant step towards ergonomic workstations and consistent quality.
People as a key to success: planning, integration and training
Reichmann provided comprehensive support throughout the project – from the concept phase through cycle time analyses and preliminary acceptance tests right through to commissioning. Intensive staff training was also a key component. After all, modern technology only delivers its full benefits when it is understood and embraced by the people using it.
Even after commissioning, Reichmann remains a reliable partner: the service covers not only the new automation systems but also the support for existing MAUS systems, including spare parts, maintenance, training and comprehensive service packages.
A prime example of the foundry of the future
Harz Guss Zorge impressively demonstrates that automation is far more than an investment in technology – it is a cultural transformation. The combination of automated core production, the Reichmann MAUS 900 and the robot-assisted RUMP shot blasting system has created a new process landscape that combines cost-effectiveness, quality and staff satisfaction.
The project exemplifies the future viability of medium-sized foundries: automation as an opportunity – not as a replacement, but as a logical step forward.