Above: The 4-head gantry system with 360-degree rotatable arms from Astes4 removes cut parts automatically. The stacked parts are then temporarily stored in the warehouse to await the next processing step.
February, 2026- SaMASZ, which builds agricultural machinery, has created a smart factory that relies on the latest robotics and storage technology from Remmert for sheet metal production.
Founded in 1984, SaMASZ is a family-owned company based in Zabłudów, Poland. The company makes more than 400 types of machines, including disc mowers, hay tedders, rakes, boom arms, working heads, flail mowers, spreaders and snow plows. SaMASZ products are distributed through a network of 30 dealers, and nearly 65 percent of production is exported to over 70 countries worldwide.
SaMASZ, in business nearly 42 years, SaMASZ increased its production efficiency significantly by introducing solutions for sheet metal processing and intralogistics during 2022.
A key element of that effort is Remmert’s sheet metal storage system, which integrates laser cutting machines, pick-and-place robots and bending machines to create the most efficient material flow.
SaMASZ’s volume of exports is achieved through subsidiaries in the United States, Germany, Great Britain and France, among others. In any production plant that operates in traditional ways, optimizing intralogistics alone can make a big difference. This has been confirmed by SaMASZ’s collaboration with Remmert, a German company. The results of this collaboration, which included consistent investment in and integration of robotic systems, far exceeded both parties’ expectations. They demonstrate how medium-sized companies can automate their production processes and ensure fast material flow.
The Remmert automatic sheet handling and storage system consists of 24 towers and 800 storage locations.
FIGHTING LOW EFFICIENCY
Prior to implementing Remmert’s automated warehouse, SaMASZ encountered several challenges that negatively impacted work efficiency and resulted in unnecessary operating costs. Another problem was the lack of a dedicated storage room. Storage outside the plant caused the steel to corrode. Additionally, the absence of a warehouse management software system prolonged logistics processes.
Furthermore, manual handling of warehouse processes posed a high risk of human error, delayed the delivery of sheet metal from the warehouse to the laser cutting machines, and placed extra strain on employees. Consequently, SaMASZ struggled with low operational efficiency, rising logistics costs, issues with timely order fulfillment and limited flexibility in responding to increased production demands.
The main motivations for introducing automation were ensuring the quality of the steel by storing it indoors, thereby preventing rust formation, and achieving a higher quality of cut parts. Another important goal was to optimize laser cutting machine utilization to maximize efficiency.
Bending machines and material processing stations are alternately lined up along the 100-foot-long row of shelves.
FULL AUTOMATION
SaMASZ now uses an advanced automatic warehouse from Remmert for sheet metal storage. It is equipped with racks to handle steel sheet formats 3015 (1183/16 by 591/16 inches) and 4020 (15711/16 by 783/4 inches). The storage warehouse measures over 73 feet high and 164 feet long. It consists of 24 towers and offers about 800 storage locations with a maximum capacity of 1.10231 U.S. tons of sheet metal.
Two Mitsubishi laser cutting machines are directly connected to the storage system. Mitsubishi ASTES4 automation form the physical interface between the laser machines and the warehouse. They enable the automatic loading of raw materials, unloading of cut sheet metal and the sorting and palletizing of up to 70 percent of the cut parts. A third laser cutting system from Prima Power, which will eventually be replaced, is manually supplied.
“We already designed the storage system to integrate a replacement laser with automation,” explains Mariusz Banachowitz, area sales manager for eastern Poland at Remmert. “And SaMASZ is at liberty to select from any manufacturer,” he adds.
After laser cutting, parts are returned to the warehouse to be buffered for the next production steps, which take place on the opposite side of the storage system. Several bending machines and material stations are alternately lined up along the 100-foot-long row of shelves. At employees’ request, pre-cut sheet metal parts are moved directly from the warehouse next to the bending machines. One of the bending machines is fully automated by a Yaskawa robot that can process large parts.
“This solution has significantly increased the efficiency and repeatability of the work. For me personally, it is an excellent example of how technology can support people in their daily tasks,” says Leszek Szulc, production manager and a member of SaMASZ’s board of directors.
SaMASZ uses 11 robots so far, including the nine welding robots that assist with crucial tasks.
AIMING FOR INDUSTRY
5.0 “The introduction of Remmert’s storage system has improved work organization at SaMASZ,” says Szulc. “This is how investing in technology can transform production towards Industry 5.0.”
SaMASZ is pushing ahead with robotization. Currently, 11 robots are in use at the plant, including nine welding robots that assist operators with crucial tasks. Szulc says the next stage of development at SaMASZ is a comprehensive digital transformation based on the synergy of people, technologies and processes.
“The program includes introducing an integrated PLM, ERP, WMS and HR system developed in line with Industry 4.0, using such concepts as the digital twin, the Internet of Things (IoT), big data and cyber - security. The future of our company lies in further robotizing logistics processes through autonomous AMRs (autonomous mobile robots), introducing cobots, and using artificial intelligence and machine learning,” Szulc says.
The goal is to develop solutions that increase efficiency, support employees, strengthen the company’s resilience and address the challenges of sustainable development. Remmert’s Banachowicz agrees: “This [installation is an] important example of international cooperation between experts in their field [and] shows that the smart factory is within reach.”
A central warehouse for raw materials, scrap, cut parts, and even partially finished products, is the basis for automation, he says, “which leads to high productivity, efficient use of space and ergonomic working conditions.”
He emphasizes that the key is integrating different systems. “Remmert is a valued partner when it comes to integrating different machines and software to create a more efficient solution. We are delighted to accompany SaMASZ on this successful journey.”
Remmert, remmert.de.
