What were the challenges to be solved and what specific benefits were achieved?
Industry 4.0 is bringing about fundamental changes in the business models of machinery and plant manufacturers. Production and logistics are merging, processes are becoming more closely interlinked, and handling tasks are becoming increasingly automated. Although these changes are leading to improved performance, flexibility and efficiency, they are also creating additional complexity. State-of-the-art hardware and software are required for managing all the processes involved.
Paced assembly can be quickly and flexibly adapted to different types of machines and systems, and an uninterrupted automatic parts supply prevents expensive downtimes. Optimal configuration of the individual work steps permits quick, defect-free assembly without any paperwork. Switch cabinets can be supplied reliably and with short lead times.
Efficiency and productivity have increased thanks to automatic storage and manufacturing in the centre for production logistics. Sawing jobs can be flexibly completed without staffing, even after working hours. Moreover, processes that are controlled by software have a very low susceptibility to faults and deliver cutting results of consistently high quality.
“By linking and digitising all of its processes in production and logistics, KASTO has gained considerable advantages in terms of flexibility and efficiency.” – Armin Stolzer, General Manager of KASTO Maschinenbau GmbH & Co. KG.
How can the Industrie 4.0 approach be described?
The switch cabinets used in KASTO’s automatic storage systems are assembled in a paced production line. They pass through a series of stations, each of which is responsible for a certain task. The production plans for sections in switch cabinets are sent from the Electrical Design department digitally, without paper, just in time to the processing machine.
KASTO also has a fully automatic material storage area for manufacturing its sawing machines and storage systems. The company’s sawing unit is seamlessly connected with it.
What could be achieved?
The work steps involved in paced switch cabinet assembly are perfectly synchronised. Components are provided at the respective station right when needed. If a component is in short supply at a station, the system reorders it automatically and sends it directly to the workstation in question. The assembly process is paperless; necessary CAD data are displayed to employees on monitors.
The material storage area likewise receives its orders in digital form and automatically. A stacker crane stores the required goods and sends them via conveyor belt to the correct saw. The machine controller automatically selects the optimum parameters and controls the sawing process. An industrial robot sorts the sawed sections as required for each order and places them automatically on pallets or in boxes.
What measures have been taken to achieve the solution?
The assembly stations are linked with one another and supplied by means of an electronic kanban solution with the necessary components in accordance with current needs. In addition, the entire production system is integrated into KASTO’s merchandise management system.
The material storage area is linked to the SAP business management solution, which also issues production orders. KASTO uses industrial robots for automatic sorting of the sawed sections. An further robot is available for deburring the sections.
What can others learn from it?
The primary beneficiaries of KASTO’s digitised, integrated production and logistics are customers. They can rely on getting sawing machines and storage systems that are free of defects and in excellent “made in Germany” quality. What is more, they benefit from fast deliveries and attractive prices. KASTO’s intelligent, efficient processes are what make this possible. Employees benefit as well. Mechanised, robot-assisted material handling minimises the risk of injuries. Workers are relieved of laborious, strenuous and monotonous tasks, and this considerably improves the working conditions.
