What's more, this investment in new, even more productive technology is happening in a production environment that is currently undergoing big changes. "This is a permanent construction site", says Welter, smiling. "More and more sensors are being built into the machines, which generate a lot of data. We're currently in the process of learning how to handle and utilise this huge quantity of data". One of the key aims of digitalising production is to allow the process to be carried out with only a few operators, or even no operators at all. 

The new Starrag manufacturing system complements this strategy perfectly because the Varel plant has recently switched to using linked systems. "We want to keep set-up separate from actual machining", says Welter. "And this works extremely well with the new ECOSPEED F 2040 FMS, where we have operators work at separate set-up stations". 

The Varel plant has been pursuing digitalisation for a long time now, since before the term "Industrie 4.0" was even coined. Consequently, the company has a systematic focus on networking. "For example, we don't have any standalone Starrag machining centres; they are all networked or linked to each other", explains Welter. "There is also the factor of security of supply, which we must be able to offer as a manufacturer of Airbus components. This is why, next to each machine, there's another one that can perform the same tasks".

So why not adopt robot handling? "The FMS currently machines 40 different components, which means we would have needed 40 actuators for the workpiece holder", explains Welter. "It also became apparent that the robot would be stationary most of the time. A cobot system would be an interesting way of facilitating set-up here. We are already robotising certain areas of small parts manufacturing, however". 

It is difficult for Welter to quantify the impact that Starrag's claim "Engineering precisely what you value" has had on his machine pool. The new investment has not been used for series production for long, he says, but its running time is 10% to 15% shorter than that of older ECOSPEED systems. 
Machine availability plays an equally big part in production at Varel, and it all comes down to manufacturer support. "Overall, we are extremely happy with the service that Starrag offers compared to that of other manufacturers", says Welter. "We've developed an excellent relationship with staff at Starrag over a very long period of time. In particular with regard to certain companies, where, due to rebranding, it's not always clear who's responsible for what".