Craftsmanship meets high tech: how Devich is automating shoe production with Zünd solutions

They’re called Zoggeli or Hölzler in Switzerland, zoccoli in Italy, and clogs in English. We’re talking about wooden shoes, footwear with a wooden sole and leather upper. Simple at first glance. But when you take a closer look at this traditional product, now being manufactured using state-of-the-art technology, a whole world opens up.

Clogs have been part of casual and workwear in rural areas for centuries. They are robust and durable, ideal for harsh climates. Traditional craftsmanship is used to produce them, often passed down through generations. This is also the case at Devich Holzschuherzeugung in Austria’s Bregenzerwald region. The family-owned business, founded by South Tyrolean shoemaker Alois Devich, is now led by the family’s fourth generation. The company has been making clogs since 1922 and currently employs 14.

Today Devich shoes are more than just functional – they are also fashionable and have become popular souvenirs. Each pair is one of a kind. Devich attaches great importance to quality, durability, and the use of natural materials.

But time doesn’t stand still even for Devich. Managing Director Daniel Devich is pursuing a clear vision: to gradually automate production while maintaining the quality of craftsmanship. One milestone on this path is Zünd's comprehensive solution for shoe production, consisting of a Zünd G3 2XL-3200 cutter with MindCUT software and a support structure for the integrated camera system, lighting, and projection. MindCUT serves as a digital control center that supports the entire cutting process, from optical hide capture and the nesting of parts to cutting and providing visual guidance during parts removal.

“I took a look at other cutters, but the Zünd is simply 
a whole other machine. It’s robust, precise, and reliable – 
everything about it is just right.”

Devich knew early on that only a Zünd system would do. His calculations finally worked out a year ago: “I came to realize that I would get a good return on investment if I used the complete solution Zünd had presented to me.”

Daniel Devich is an entrepreneur, developer, and visionary, but he is also a practical man. What drives him is efficiency. Not as an end in itself, but as part of his philosophy for doing business. “The pursuit of efficiency is deeply rooted in our company’s DNA. That's what drives me,” says Devich. “Back in the day, even my grandfather combined craftsmanship with machines that made his job easier; they're what made him more efficient and more successful than his competitors.” Devich’s company has been using CNC routers for making clogs for the past 30 years.

Throughout its history, the traditional family business has consistently invested in new technologies. Daniel Devich, a technology enthusiast, doesn’t actually have a background in shoemaking. He often enjoys spending his free time programming software. But as a successful entrepreneur, he understands that automation needs to be cost-effective and pay off in the long run. Moreover, it has to meet his high standards for the quality and design of his shoes.

How can tradition and craftsmanship be reconciled with increasingly automated, efficiency-oriented production? How can craftsmanship go hand in hand with state-of-the-art, increasingly autonomous production systems?

Listening to Devich, it becomes clear what kind of entrepreneur he is. Long-time family values are more important to him than maximizing profits or increasing production volumes. The market is already saturated, and the clogs are too durable and too high quality to allow for significant growth in this area. For Devich there is much greater value in optimizing internal processes. Digitalizing cutting and using MindCUT software to grade hides and efficiently nest parts for maximum material utilization were the logical next steps. Says Devich, “I am constantly trying to increase our depth of production and grow through higher added value.”

Devich produces approximately 20,000 pairs of shoes each year. That’s about 80 pairs per day. At first, that doesn’t sound like a whole lot. So why the need for more automated and efficient production processes for relatively small batch sizes? The company’s product portfolio is broad, and customers can choose from different leathers and hides, with shoe sizes ranging widely from 23 to 52.

In addition, Devich also sells shoes through its online store. Approximately one fifth of the company's sales are generated online. The focus here, too, is not on further growth; instead, the goal is to offer better customer service. For example, customers can go online outside of store hours to buy shoes that are sitting on store shelves. Every shoe is one of a kind. And perhaps the shoes of your dreams, with the exact fur pattern and color you want, might already be waiting for you on the shelf. Now you can order them with the click of a mouse. Or, you can reserve them and try them on later in the store. “Shoes are something people like to try on.”

Devich knew right from the start that only a Zünd would do when it came to digitalizing the cutting of his leather and hides. “I took a look at other cutters, but the Zünd cutter is simply an entirely different machine. It’s robust and reliable – everything about it is just right.” In 2024, he finally came to the conclusion that the investment would pay off and provide a good return. “The purchase was the next logical step and another piece in the puzzle in our journey to automated shoe production – with high-precision hardware and a smart software solution.”

“I’ve seen other systems, but Zünd is simply in a class of its own. 
Everything is the way it should be – from the initial 
consultation to the machine and the support.”

But let's get back to the variety of materials. While the sole is still made of wood, a lot has changed in terms of uppers. Today customers can choose from smooth leather, from Italian or Brazilian cowhide, or from goatskin, with or without fur lining. Each hide and piece of leather is unique, with its own distinctive color or pattern.

The software-assisted nesting of cut pieces on leather and hides is an art in itself. Here, for Devich, aesthetics sometimes take precedence over efficiency. “The shoes need to match visually as a pair. That means leather color, grain, fur length and pattern need to be the same. People love symmetry, but hides are actually the exact opposite. Finding a great pair is a perpetual challenge.”

• Optical capture and recognition and a camera system controlled by MindCUT software for automatic or manual nesting
• Smart nesting for maximizing material utilization
• Precise cutting of leather and hides
• Flexible processing of different types of leather and hides

Daniel Devich is not only the head of a company, he’s a developer, craftsman, and visionary. He knows why for him a Zünd cutter was the only viable option:

• Robust and durable technology
• Modular design allowing for future expansion
• Open, honest advice
• A willingness to support new ideas

Devich manufactures approximately 20,000 pairs of shoes each year. At this volume, every step of the process counts. The complete solution, which consists of MindCUT software and a Zünd cutting system, pays off in more ways than one:

• Higher precision and repeatability
• Less manual cutting required thanks to smart order processing
• More space for new models
• Continually increasing levels of automation through software-assisted processes

Despite all the technology in use, each pair is still one of a kind. With hides in particular, aesthetics often take precedence over maximizing material usage. “The shoes need to work as a pair – same grain, similar color, same pattern. It takes a delicate touch to achieve that.”

Devich’s grandfather already combined craftsmanship with technology. Now, Daniel Devich uses CNC routers, does programming in his spare time, and runs the company with a keen sense of quality and innovation. He views automation as an opportunity rather than a risk, even for smaller batch sizes. “I’m the brain of the company, but I’m also its hands. The Zünd cutter gives me another hand. MindCUT helps control the whole process. Perhaps some day, it may just become an extension of our brain.”

The partnership with Zünd goes beyond technology. What matters is the combination of consulting, mechanical-engineering expertise, and openness. This is especially important in an environment where individuality and tradition are key. Automation does not have to be impersonal.

• Precise, material-saving cutting – ideal for manufacturing companies
• Scalable – even for smaller production runs
• Personal support – instead of standard solutions