HAHN Automation Group x montrac®

The Company

Global Expertise in Factory Automation

The HAHN Automation Group is a leading international solution provider in the field of factory automation. With over 1,600 employees at 20 locations worldwide, the company offers a wide range of solutions – from manual processing stations and semi-automated cells to fully automated lines.

Customers from the automotive, electronics, and medtech industries benefit from over 30 years of technological experience, a comprehensive project portfolio, and a consistent focus on service.

The offering is complemented by a digital product portfolio that provides manufacturing companies with efficiency advantages and supports them on their way to becoming smart factories.

The long-standing global partnership with montratec GmbH forms the basis for over 20 assembly lines in which the advantages of modular transport solutions such as montrac^® prove themselves every day.

The Initial Situation 

Focus on Complexity And Flexibility

Before integrating montrac^®, HAHN was confronted with increasing demands for flexibility and efficiency in production. The development of special-purpose machines for various industries requires the ability to respond to a wide variety of product geometries and sizes. Especially in highly automated lines, uninterrupted and reliable parts supply between the individual stations is essential.

At the same time, production layouts had to be designed to be as space-saving and modular as possible — especially in retrofit projects with limited space.

The Solution

montrac^® as Key Technology For Modular Automation

To meet these challenges, HAHN decided to use the montrac^® system from CMCO Conveyance Solutions. The decision was based on a number of technical and economic advantages.

The compact design of montrac^® allows for tight curve radii, height bridging, and efficient use in confined spaces. The system can really show off its strengths, especially in retrofit projects. The decentralized intelligence of the system lets each shuttle act autonomously, which takes some of the load off the central control system, increases reliability, and makes it easier to integrate into existing machine concepts.

Another key advantage is the low-maintenance technology. Contactless energy and data transmission significantly reduces mechanical wear. This not only increases system availability and service life, but also measurably reduces operating costs. Gentle, low-impact product handling protects sensitive components and is ideal for complex geometries—an important criterion when processing sensitive components in medical technology or electronics manufacturing.

In addition, the system is technically reliable, ESD-compatible, operates at a quiet 65dB, and impresses with its very low power consumption. The system is also efficient in terms of the number of workpiece carriers required — fewer carriers mean lower investment costs and less effort during operation.

The Progress of The Project 

Digital Planning, Fast Implementation

The integration of montrac^® at HAHN was carried out in close cooperation with the in-house engineering team. “HAHN Virtual” was already used in the planning phase – a platform for virtual commissioning that allows layouts, cycle times, and the required number of shuttles to be simulated precisely in advance. With the help of this digital twin, various concepts were tested, potential bottlenecks identified, and the system optimally adapted to the project requirements.

The modular structure of montrac^® enabled easy mechanical integration into existing systems and significantly reduced commissioning time. In close cooperation with the project team, layouts were finalized, interfaces standardized, and software modules transferred to the HAHN automation platform based on the system requirements. These were created with the help of a code generator and will be part of the internal engineering standard in the future—an investment that will also pay off in future projects.

Measurable Results 

Flexibility And Efficiency in Series Production

The results of the project speak for themselves: System availability is consistently above 95% — a critical success factor in fully automated production. The modular system structure and easy integration into existing HAHN systems have significantly reduced commissioning times.

The flexibility during product changes or site relocations was rated particularly positively: montrac^® can be quickly adapted to new requirements, enabling short-term responses to changing market conditions.

In addition, maintenance and service teams benefit from easy accessibility and low-maintenance design. The positive feedback from various customer projects confirms the added value of the solution – both on a technical and operational level.

Thanks to the experience gained with the system, the HAHN Automation Group is now in a position to quickly implement montrac^® solutions in future projects and scale them multiple times – on a uniform engineering basis with standardized interfaces.

Conclusion

The Next Level of Automation

The project impressively demonstrates how increasing demands for flexibility, availability, and sustainability can be met through an intelligent combination of digital planning, modular technology, and innovative transfer systems.

With CMCO Conveyance Solutions as its strategic partner, the HAHN Automation Group is able to implement high-performance automation solutions that meet not only today's requirements but also those of the future — efficient, scalable, and low-maintenance.