The
Böllinger Group, based in the German town of Bad Friedrichshall, has long been recognised for its expertise in high precision prototyping and small-batch manufacturing. Known for delivering exceptional quality and flexibility, the company faced a pivotal moment in 2023 when a demanding customer project required a shift to industrial series production for the first time in its history.
Thomas Gilliar, managing director of the Böllinger Group, said: “This was more than just a technical upgrade. We wanted to expand our portfolio and at the same time demonstrate that we can also meet the highest standards in series production. To do this, however, we needed not only the right technology, but also a partner who could support the entire project from a single source – technologically, organisationally, and digitally.”
Following a thorough market analysis, the company selected
Grob as its strategic partner. The decision was driven not only by Grob’s extensive machine portfolio but also by its ability to deliver complete process chains and integrated digital solutions. The project moved swiftly from concept to execution. Just days after the initial meeting, Grob presented a tailored solution. Mr Gilliar recalled: “We were impressed by how quickly Grob not only understood our requirements but also translated them into a feasible concept.”
Planning, delivery, installation, and commissioning were all completed on schedule, enabling Böllinger to meet its customer’s tight deadlines. At the core of the new production line are two G320 two-spindle machining centers, integrated into a third-party automation system. This setup includes automated workpiece feeding, high-pressure cleaning, vacuum drying, and visual inspection – a comprehensive solution that enabled Böllinger to transition smoothly into series production.
Full transparency of production processesDigitalisation played a central role in the transformation. With GROB-NET4Industry, the manufacturer gained full transparency over its production processes. Peter Feucht, Böllinger’s production manager, said: “GROB4PartFlow provides us with a complete history of every manufactured component at the touch of a button. If we have any queries or need to evaluate quality, we can trace at any time which part passed through what station.”
Furthermore, machine status, alarms, and performance metrics are now accessible in real time via GROB4Line, improving responsiveness and reducing downtime. Sebastian Hübner, series production team leader, said: “Our response times have improved significantly. This means that faults are detected earlier and downtimes are reduced.”
GROB4Analyze further enhances operational efficiency by evaluating machine data in real time. This enables early detection of process deviations and quality trends, supporting continuous improvement. Benedikt Gundling, product manager for digital products at Grob, said: “With GROB4Analyze, we are providing our customers with a tool that not only increases efficiency but also enables comprehensive process data monitoring and sustainable quality improvement.”
Tool management has also reached a new level with GROB4TDX. Particularly beneficial in prototype production, where frequent tool changes are common, the system allows for digital management and automatic synchronisation of tool data. Stefan Kniel from Work Preparation, said: “Tool data can be easily transferred, synchronized, and documented by scanning, which significantly increases process reliability.”
Milestone in collaborative innovationFor Grob, the project marked a milestone in collaborative innovation. Mr Gundling continued: “We didn’t just deliver machines here, we ushered in a new era together with the customer. It was important to us to act as an equal partner from the very beginning – with a high level of technical expertise, but also with a great deal of flexibility and commitment. Medium-size companies that want to move toward Industry 4.0 need solutions that not only work technically, but also bring real added value in everyday use. That is exactly what we have achieved here together.”
The result is a highly efficient production line that not only meets but exceeds Böllinger’s expectations. Mr Gilliar added: “The new production line has enormous appeal. We regularly receive new project enquiries and are already working on further concepts with Grob.”
Reflecting on the journey, Mr Gilliar emphasised the importance of practical digitalisation: “Our employees see that digital tools help them – in planning, in evaluation, in their daily work. This promotes acceptance and willingness to embrace new technologies.”
His advice to other manufacturers is clear: “You don’t have to make digitalisation complicated – but you have to take it seriously. Only those who understand processes can digitalise them. With Grob, we had a partner who accompanied us on this journey not only technically, but also on a human level.”