Representing the Tauberfranken region is WITTENSTEIN SE, which develops, manufactures, and markets gearboxes, motors, and electronics, as well as high-precision drive systems and solutions, nanotechnology, and specialized software solutions. A family-run, technologically highly specialized hidden champion.
On an assembly table lie gears with a bore. Small boxes containing metal pins, known as needle rollers, stand neatly lined up beside them. A long brush applies grease to the bore. A pair of tweezers picks up the small needles. It inserts them: grasp, insert, grasp, insert. It is not a robot working here, but a woman with nimble hands.
Among other things, WITTENSTEIN manufactures high-quality, low-backlash planetary gearboxes - for applications where the highest precision is required, such as in automation technology, aerospace, and medical technology. Each application area requires its own type of grease and “needling.” Errors are not permitted here, especially not in gearboxes for the food industry.
Engineers Markus Grein, Konstantin Michels, and Dr.-Ing. Lars Aldinger are working on a new development of the needle-lubrication process. The three agree: “We need to streamline the processes and make them safer.”
Bringing Ideas to Life with a Cardboard Prototype
This is where the four TUM students come in: Burak Toca, Ahmad Hussainzada, Leonard Krümel, and Sakhobiddin Abdukhakimov. For a week, they immerse themselves in the process — as idea generators and discussion partners, but also as hands-on practitioners. They build a mockup to address the problem: a workstation made of cardboard and wood. And they clearly enjoy it. “Here we can see right away what works and what doesn’t,” says Sakhobiddin, who is pursuing his master’s degree in Management and Digital Technology at the TUM Campus Heilbronn.
The four are also learning about “Poka Yoke,” the Japanese principle of quality management. In short: designing things so that errors cannot happen in the first place. They are implementing this with concrete ideas on the model. “Grease Cubes” will later be used there, dispensing the correct grease depending on the application; an LED system indicates which grease is currently being used.
A Fresh Perspective from the Outside
Project supervisors Grein and Aldinger have deliberately brought the university perspective on board. “Assume that you don’t know everything,” says Markus Grein. And he adds: “We need a change of perspective from the outside.” Close collaboration with the students brings a breath of fresh air to the development process. And perhaps even the occasional unconventional approach.
“This is a really well-thought-out project,” says Leonard. He is studying Robotics, Cognition, and Intelligence. At the end of the week, the students present their model to the engineers at WITTENSTEIN. “The semi-automated solutions are well-received,” Leonard says happily. And Ahmad adds: “I learned something I had never encountered before in lectures. That was a great practical experience.”
Will the recommended solution make the lady with the nimble hands redundant? No. At WITTENSTEIN, people remain central. Technology is meant to support, not replace. The students have done their part to ensure that the pinning process will be more ergonomic, safer, and simpler in the future.
Are you interested in the TUM 1.000+ Project Week? Feel free to contact us: 1.000plus(at)cit.tum.de.