Managing 7-inch reels at the core of the automation process
BMK Group entrusted us with the transformation of its storage processes by integrating ESSEGI AUTOMATION’s automated systems into its traditional warehouse, with a specific focus on handling 7-inch reels. The project resulted in the installation of two configurations composed of ISM Ultraflex 3600 units combined with ISM Ultraflex 3900 modules, all coordinated by the ISM Software and fully connected via API to the ERP and material management systems.
This implementation enabled BMK to automate material preparation, significantly reduce manual handling, ensure full traceability, and make SMT flows faster, more flexible, and highly reliable.
Company: EMS Area: Augsburg, Germany (Europe) SMT lines number: 4 SMT Pick&Place lines Brand Pick&Place: ASMPT Products: Ultraflex series ISM 3600, Ultraflex series ISM 3900, ISM Software
The introduction of ESSEGI systems has been much more than a technological upgrade: it has transformed our material management, making every process faster, safer, and fully traceable. It is an investment that prepares us for the future, and one that our teams experience daily in their operational work.
The Starting Point in BMK Group
BMK Group, active for over 30 years as an EMS partner, supports its customers throughout the entire electronic development and manufacturing cycle. With more than 1,500 employees across Europe and Asia and a total production surface exceeding 80,000 m², the group stands as one of the key references in the field.
In 2024, the new Augsburg plant was inaugurated, managing over 500 production orders per month and more than 10,000 material packages, with machine reconfiguration occurring on average every 30 minutes.
Such a level of dynamism required a compact and fully integrated automated storage solution capable of accelerating material preparation while ensuring full traceability and enhanced process security.
The solution that optimizes 7-inch reels management
To meet the needs of the new Augsburg site, BMK installed two ISM Ultraflex 3600 systems, each expanded with an ISM Ultraflex 3900module. The main objective was to optimize the management of 7-inch reels, which represent the largest portion of handled material. Thanks to ESSEGI AUTOMATION’s systems, the company achieved both a significant space saving in the production area due to the high storage capacity, and a fully automated material handling process that minimizes manual intervention.
The automated warehouse systems now operate in parallel with manual picking, making the entire material flow faster and more efficient. Furthermore, thanks to the accurately engineered API interface with BMK’s ERP, picking lists are transferred directly, ensuring fast and repeatable material preparation.
Space optimization: high-density management of 7-inch reels with a significant reduction in required floor space
Faster material preparation: automatic picking works in parallel with manual retrieval, with lists transferred directly from the ERP, accelerating preparation for SMT lines
Setup Time reduction: automated flows enable faster machine reconfigurations and continuous product changeovers without slowdowns
Higher operational efficiency: Warehouse personnel can focus on higher-value tasks, reducing manual search and handling activities
Full Traceability: ESSEGI systems ensure complete material tracking, improving data quality and process transparency
Process & IT Security: All positions are autonomously managed by the system and API interfaces, increasing reliability and protection of operational flows
Production continuity: The warehouse configuration ensures operational continuity even in case one system is temporarily down, maintaining material transparency and availability
