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Efficient cable identification process at PMB Slovakia
Efficient cable identification process
PMB Slovakia is optimizing its cable identification process with a customized solution from Phoenix Contact. The combination of the THERMOMARK E SERIES and a customized software solution creates an efficient process that significantly simplifies cable identification.
PMB Slovakia is a specialized manufacturer of cable harnesses and customer-specific wiring solutions for a wide range of industrial applications. Since its founding in 2006, the company has established itself as a reliable partner for international customers and offers both the development and series production of cable assemblies. In a demanding production environment, PMB manufactures everything from small batches and custom-made items to mass-produced goods. Efficient and reliable identification processes play a key role in ensuring productivity, traceability, and consistently high product quality. PMB places a strong emphasis on quality, flexibility, and modern production technologies.
Initial situation and objective
Previously, cable identification at PMB Slovakia was performed in an open production area using standard roll printers. The labels were printed separately, prepared manually, and then applied by hand. This process required a significant amount of effort and led to inconsistencies in quality and efficiency. As production demands increased, PMB sought a solution that would optimize operations, reduce manual work, and improve the reliability of the entire process. At the same time, user-friendliness played a key role. Employees needed to be able to use the system intuitively and directly at their workstations. One key requirement made this project particularly unique: PMB wanted a solution that could work without a desktop PC or complex identification software.
Procedure and approach
The project kicked off with a proactive presentation of the THERMOMARK E SERIES from Phoenix Contact. PMB immediately recognized the potential for increased efficiency with the THERMOMARK E.WRAP applicator. However, the requirement to enable operation without a desktop PC presented a challenge that could not be met by standard solutions alone. As a result, Phoenix Contact initiated close collaboration between the local teams and its own software specialists. Working closely with the customer, a customized solution was developed over the course of several test phases and continuously optimized. In order to validate the application under real-world production conditions, a loan device was used during this period. This collaborative approach, combined with strong technical support, ultimately led to a successful implementation.
Printing and application in a single step
THERMOMARK E SERIES
The THERMOMARK E SERIES ensures greater efficiency: Comprised of a thermal transfer roll printer and applicators, the modular system prints labels and applies them to cables and wires in an automated process. The combination of these process steps results in time savings of around 60%.
The THERMOMARK E.300 D printer used at PMB, in combination with the THERMOMARK E.WRAP applicator, processes E-WML … self-laminating wire-wrap labels for the identification of cylindrical objects such as wires, cables, and hoses. The system automatically prints and applies the wrap-around labels in a single step. Thanks to the protective laminate, this identification solution provides an exceptionally durable marking that is protected against dirt and abrasion. Because they are wrapped tightly, the labels do not add any extra bulk, so wires and cables can be easily pulled through cable ducts, for example.
At the heart of the application is a customized software solution that enables direct control of the printer. Instead of relying on a PC-based workflow, all relevant marking data is processed centrally and transmitted directly to the device. In production, the process is deliberately kept simple. Operators select the appropriate marking job by scanning a barcode, define key parameters directly on the printer display, and start the process with minimal effort. The flexible labels can include, for example, serial numbers, product-specific manufacturing data such as the calendar week and year, as well as dynamically adjusted content, depending on the available space. This solution was implemented through targeted programming directly on the printer via TCP/IP. Using technologies such as JScript and printer-specific command languages, Phoenix Contact developed an application that is precisely tailored to the customer’s requirements.
Higher productivity: Markings are printed and applied in a single step. This eliminates intermediate steps and significantly speeds up processes.
Less manual effort: Automated processes and an intuitive workflow significantly reduce the workload on employees, minimize the potential for errors, and ensure consistently high quality.
High degree of flexibility: Flexible selection of marking projects via barcode scanning is possible, making it ideal for a wide variety of product versions and changing production requirements.
Easy operation without a PC: The printer is activated via a barcode scanner. It is possible to set individual parameters and view progress on the printer display – no software required.
Through close collaboration with Phoenix Contact and targeted development that goes beyond industry standards, we have created a solution with future viability that is optimally tailored to our requirements for modern cable assembly.
Summary
With the introduction of the THERMOMARK E SERIES, combined with a customized software solution, PMB has fundamentally optimized the identification process. By combining printing and application into a single, streamlined process step, preparatory tasks are eliminated, which significantly reduces manual effort and noticeably speeds up workflows. At the same time, the standardized workflow ensures greater process reliability: The influence of human factors is minimized, the risk of errors is reduced, and consistent, high-quality identification is ensured. In addition, the solution offers a high degree of flexibility in its application. Different marking formats can be quickly selected and customized, allowing for an efficient response to changing requirements, even with a wide variety of products and small batch sizes. Its PC-independent operation also simplifies integration into the manufacturing environment and reduces complexity in day-to-day production.
