Kurtz News 31 - the kurtz ersa Corporation

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Flow production
starts at ERSA
By Dr. Helmut Diehm
Already one year ago, we reported on our
cooperation with Porsche Consulting and
the subject of „waste-free enterprise“ in
our group of companies. In the meantime
we implemented the specially trained HIP
Project Management Organisation of the
Kurtz Group.
For the ERSA Machines business
division, we decided on attacking the
change of the production system itself.
With the help of the HIP coaches for the
project management, the project was
prepared and initiated.
To start with, assistance was given in the
conceptual preparation and in workshops.
Until a stable process will have been
achieved, the complete flow production,
with its particular requirements regarding
logistics, will be continuously supervised
and supported with instructions.
In early May, the „conveyor belt“ for a
synchronised and capacity-smoothed
assembly started in machine production,
Now, highly complex machines are
assembled in eight equal cycles.
New flow production:
Since May reflow soldering
machines are manufactured in
synchronised production at ERSA
Zero defects culture
This cycle currently amounts to four
hours. To make this possible, interfaces
for components, pre-assemblies and
the basic machine itself were analysed
and some of them even redefined.
Standardisation of the working steps
already led to continuous improvement in
the individual work stations.
Likewise, a start has been made of
completely reorganising the logistics
process, which already has its effect with
reductions in stocks. This applies to both
the specifically machine-related parts and
also to the so-called bulk goods. To avoid
over-production, the “demand pull” system
is now in mandatory use, instead of filling
components assembly as well as pre- and
final assembly with “push” stocks.
As early as the start of the project, it
became clear what the new zero defects
culture means for all areas. Errors can
no longer be „covered up“. Immediately,
the „status lights“ turn to amber or, in
an extreme case, to red. Never in the
past has remedying them been done
as consistently and as quickly as now.
Thanks to continuous flow processes,
the real problems are clearly shown.
In the traditional way of thinking a
standstill of the own production (status
light is red) appears like a catastrophe.
But this is an essential and „deliberate“
effect of the „one-piece flow“. Everyone
is affected and everyone and every
hierarchic level is forced to solve
the problem. Prevention is given the
necessary importance.
A change has rarely been taken over by
the employees directly affected by it with
so much acceptance.
Our broad network of business
partners and suppliers will increasingly
be affected. Our demands on the
suppliers will increase with respect to
organisation and quality. We want our
increasing excellence standard also to
be accompanied by permanently rising
standards with our business partners.
We will be pleased to help our partners
in this regard. It is a question of a wellfounded
partnership and joint growth for
mutual, long-term benefit.
Non-stop operation:
Robot system operates the
new bending press at MBW
By Alexander Schmidt
As early as 2005, MBW Metallbearbeitung
Wertheim GmbH took a decisive step in
the direction of securing the future and
the location with its new building. In the
same year, also the automation of sheet
metal production was started. As a result
of the new investment in a punching
machine, which is connected to a fully
automatic sheet metal warehouse, orders
can be handled with high efficiency. A
third man-free shift became possible for
the first time. Last year, a new 5 kW laser
was also connected to this sheet metal
warehouse. Larger throughput numbers
in material cutting are now facilitated
more quickly and more favourably. As a
logical consequence under the aspect of
the technological lead according to the
Kurtz Vision, automation in the area of
bending followed with the investment into
a so-called bending cell.
A bending cell is the combination of a con-
MBW with new bending cell
Automation guarantees
even more process reliability
ventional chamfering press with a robot.
In the case of MBW it covers a maximum
chamfering length of up to 4 m. The use of
vacuum grippers and optional mechanical
grippers for small parts allows a high
spectrum of parts. The tool clamp, which
is 4 m in length, makes it possible to bend
even complex parts in one processing
sequence without a change of tools. The
maximum weight of the parts is 40 kg.
Unlike the problems in conventional,
manual bending, where even the best
machine operator fatigues after hours of
bending identical parts and runs the risk
of jamming parts, the robot works without
breaks and with high precision. The
process reliability is increased.
A sheet metal sensor integrated into
the gripper arm ensures recognition of
the pile of sheet metal and the correct
collection of the part to be bent. In the
actual bending process, the bending
angle sensors automatically ensure
regulation of the angle to the required
nominal figure. Each angle is correct at
the first attempt. Complicated running-in
phases of bending programmes with the
necessary trial parts are now a thing of
the past. The change of the resilience
angle as a result of differing materials and
material properties is independently and
automatically attended to by the system.
Economic production is possible from a
batch size of 30, sometimes even less,
if the necessary programmes „only“ have
to be loaded for recurring parts.
In addition to the benefits already
mentioned, there is also the flexibility
of the system, under the aspect that
the bending cell can also be operated
manually at any time. For this purpose,
the robot moves to a parking position
outside the actual working area.
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