Erowa AG is active in metal processing in the field of clamping technology and automation and is a world leader with its solutions. Like many Swiss industrial companies, Erowa is also concerned with the issue of cost pressure due to the strength of the Swiss franc, the shortage of skilled labour and the need to secure know-how.
For the UPC chuck, there was a need to significantly shorten the assembly process and at the same time distribute the expertise more widely across the department. Until then, assembly had been carried out in batch production, which was common but time-consuming. The biggest challenge was to switch from the previous batch production to the more efficient one-piece flow. It was crucial to get the employees on board with this change and not simply adopt the assembly process, but to rethink it from the ground up.
To initiate the changeover to the one-piece flow and experience the benefits for themselves, Phoenix Mecano proposed a practical approach: a LEAN live workshop. A team from Erowa and a LEAN expert from Phoenix Mecano came together in a specially equipped room with provisional work tables, shelves and standard modules. The aim was to develop the new assembly process together. Erowa brought all the individual parts to Stein am Rhein for this purpose. After demonstrating and analysing the current assembly process, the next step was to integrate the process into an assembly workstation. The workstation was customised step by step using cardboard boxes and modules, while the product was assembled live. The practical implementation and direct feedback from the employees during the workshop made it possible to adapt the workstation ideally and create a lean assembly island that ensures an optimal workflow. Experience has shown that it is crucial to actively involve those employees in the process who are familiar with assembly and who will also be assembling the product in the future. They understand the challenges best. It is equally important that these employees experience the advantages of one-piece flow assembly directly and are convinced of the effectiveness of the new working method. At the end of the day, a rough reduction in assembly time could be measured.
Phoenix Mecano then used the assembly island to develop the assembly workstation in CAD. At the workshop, it was realised that the chuck, which weighs over 30 kg, has to be rotated or set up several times during assembly. Phoenix Mecano developed a pneumatic rotating and swivelling device for this purpose, allowing the assembler to continue working with both hands with minimal interruption. Finally, a SETAGO® worker guide was used to support assembly and safeguard expertise. The worker guide leads the user step by step through the assembly process. Light sensors on the container indicate where the component to be assembled is located, while the work step is explained on the screen using text, images or video. Thanks to targeted digitalisation with SETAGO® worker guidance, the chuck can now be produced independently of employees. The final result of the collaboration was a noticeable reduction in assembly time, which led to a significant increase in productivity. This meant that all of Phoenix Mecano Solutions AG's objectives were successfully realised.
Phoenix Mecano then used the assembly island to develop the assembly workstation in CAD. At the workshop, it was realised that the chuck, which weighs over 30 kg, has to be rotated or set up several times during assembly. Phoenix Mecano developed a pneumatic rotating and swivelling device for this purpose, allowing the assembler to continue working with both hands with minimal interruption. Finally, a SETAGO® worker guide was used to support assembly and safeguard expertise. The worker guide leads the user step by step through the assembly process. Light sensors on the container indicate where the component to be assembled is located, while the work step is explained on the screen using text, images or video. Thanks to targeted digitalisation with SETAGO® worker guidance, the chuck can now be produced independently of employees. The final result of the collaboration was a noticeable reduction in assembly time, which led to a significant increase in productivity. This meant that all of Phoenix Mecano Solutions AG's objectives were successfully realised.
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