Inline Vision & Weld System + Marking On The Fly Sets New Standards for Process Reliability and Traceability in Stamping Technology
Challenge: Pursuing a Zero-Defect Strategy Amid Increasing Requirements
The KRAMSKI Group, a globally leading specialist in sophisticated stamping and hybrid technologies, supplies OEMs and Tier 1 suppliers worldwide in industries such as automotive, electronics, e-mobility and medical technology.
Across these sectors, requirements continue to increase:
- 100% quality control in series production
- Zero-defect strategy
- Complete traceability
- Maximum process stability and efficiency
- Cost-effective, highly automated manufacturing
At the same time, trends such as miniaturization, electrification and intelligent systems are driving product and process complexity.
Against this backdrop, it was essential for KRAMSKI to further develop its production line with the goal of detecting quality deviations at an early stage, automating processes and avoiding production downtime.
Solution: Inline Vision & Weld System with Marking On The Fly
Developed in collaboration with Kistler and Nidec SYS, the Inline Vision & Weld System (IVWS) combines several process steps in a single module for the first time:
- High-speed marking (Marking On The Fly)
- Optical inline inspection
- Removal of defective parts
- Laser welding of the stamped strip
The result is a highly compact, fully integrated system for automated quality control in stamped part production.
Optical quality inspection and laser marking
Defect part removal and laser welding technology
Increased Automation: Eliminating Downtime and Manual Intervention
Inline Vision & Weld System permanently integrated into the production line
One of the key advantages of the solution is its significantly increased machine autonomy. Without a cut-and-weld solution, the press would stop whenever a suspicious part is detected.
With the IVWS + Marking On The Fly:
- Production continues even when defective parts are detected and removed, as the strip is automatically reconnected by laser welding.
- Downtime is significantly reduced.
- Adjacent good parts remain protected.
- Manual operator intervention is eliminated.
- Unattended “lights-out” production becomes possible.
The result is a continuous coil consisting exclusively of verified, defect-free components, ideally prepared for downstream processes.
High-Speed Traceability with Marking On The Fly
Another highlight of the system is the integrated Marking-on-the-Fly-(MoF)-Modul:
- Marking of up to 1,600 parts per minute
- QR codes, barcodes and customer-specific codes
- Complete traceability of every individual component
This functionality is particularly valuable for industries with strict regulatory requirements, including:
- Automotive
- Electronics
- Medical technology
In addition, the system generates valuable real-time data for process optimization..
Example: Stamped Strip
Collaboration on Equal Footing
The project was characterized by close and collaborative teamwork:
“The collaboration was constructive, solution-oriented and always based on partnership. Challenges were analyzed jointly and implemented pragmatically.”
Stefan Lau, Process Engineering KRAMSKI
This collaborative development approach proved to be a key success factor, particularly in integrating the various technologies into a unified system.
Strong partnership: Experts from KRAMSKI, Kistler and Nidec SYS collaborating closely.
Operational Benefits
Since implementation, KRAMSKI has benefited from several significant advantages:
Production Reliability & Quality
- Reliable detection of suspicious stamped parts
- Prevention of customer complaints
- Validated process reliability
Efficiency & Machine Availability
- Reduced unplanned downtime
- Increased autonomous operating time
- Foundation for autonomous production
Ease of Operation
- High employee acceptance
- Intuitive operation
KRAMSKI employee operating the system – efficient, user-friendly and well accepted by operators.
Conclusion: Future-Proof Manufacturing Through Intelligent Integration
Following successful optimization, the Inline Vision & Weld System + Marking On The Fly has established itself as a robust, industrial-grade solution.
The project objectives have been achieved:
- Higher degree of automation
- Improved process reliability
- Maximum machine availability
At the same time, the system creates the foundation for future enhancements, such as new products and additional inspection features.
Outlook: Data-Driven Manufacturing as a Key to Competitiveness
In response to increasing quality requirements and growing global competition, KRAMSKI continues to invest in advanced technologies:
- Automated inline inspection systems
- Digital process monitoring
- Data-driven optimization
The goal is clear: to manufacture the highest-quality products efficiently, economically and with maximum flexibility.
“Our ambition is to continuously push technological boundaries and manufacture the highest quality products in a cost-effective way. The Inline Vision & Weld System, implemented together with Kistler and Nidec SYS, helps us consistently execute our zero-defect strategy and further advance the automation of our production.”
Philipp Perez Castillo,
Head of Tooling & Equipment Manufacturing, KRAMSKI
