Workshop planning with efficient workstation solutions With the goal of creating a future-proof, efficient, and ergonomic production environment, PGA Automation GmbH, in collaboration with Phoenix Contact, has created a comprehensive workshop layout in its new production hall and fundamentally modernized its production processes. The collaboration focused on digital factory planning and customized workstation design. This has resulted in measurable improvements in productivity, process reliability, and employee satisfaction.

PGA Automation GmbH, based in Sinsheim, Germany, has been an experienced partner in the field of switchgear and control system engineering for over 25 years. The company develops customized solutions for electrical power distribution and covers the entire value chain – from planning and design to production. The portfolio includes low-voltage switchgear up to 2,500 A, meter cabinets, power and load distribution boards, and automation and control cabinets.

As the company grew and moved into a new production hall, PGA faced the challenge of making its production processes future-proof, flexible, and efficient. The goal was to make lasting improvements in quality, production time, and ergonomics, and to align production with the requirements of modern energy and building technology as well as e-mobility solutions.

During the first phase – factory planning – a 3D layout of the production facility was developed in collaboration with Phoenix Contact, laying the foundation for structured and future-proof production. A key element was the decoupling of process steps: The functional areas were designed to be process-oriented, allowing tasks to be carried out in parallel or prepared in a targeted manner. In addition, a comprehensive material flow analysis was conducted with the aim of identifying and eliminating unnecessary routes.

In the second phase, the focus was on the workstation design. The experts from Phoenix Contact and the staff at PGA worked together to design modular, ergonomic, and process-oriented workstations for wiring and terminal strip production. In addition, special project trolleys were developed, which, as order picking trolleys, are individually tailored to customer projects and enable optimum use of space.

• More efficient material flow
  By analyzing and strategically reorganizing storage, transportation, and work areas, it was possible to reduce unnecessary routes and thus make material flow much more efficient.

• Reduced production times
  Decoupling the process steps enables parallel workflows and greater flexibility in production. Optimizing the balance between workstations and storage areas prevents bottlenecks and reduces wait times.

• Improved ergonomics and process reliability
  Ergonomically designed, mobile, and organized workstations reduce the time spent searching for items as well as setup time. The clear organization of tools and materials ensures efficient, uninterrupted work and also provides a high degree of process reliability.

• Decoupled terminal strip design
  The workstation solution developed with worker assistance software and a pick-by-light system guides employees intuitively through the mounting process. This reduces errors and allows for the targeted deployment of semi-skilled workers. Since materials are delivered directly to the workstation, there is no need for order picking.