Efficient control cabinet building with optimized processes Efficient control cabinet building does not necessarily begin with comprehensive automation. Often, organizational improvements – such as clearer processes, shorter paths, and an improved material supply – are enough to noticeably improve productivity and working conditions. This demonstrates the collaboration between KSK Elektro Technik Automation and Phoenix Contact.

KSK Automation GmbH, headquartered in Haltern am See, Germany, is part of a family-run group of companies and specializes in automation and control solutions for industrial systems. The company supports projects from planning, through programming, right through to commissioning, and also manufactures low-voltage switchgear. The core areas of expertise include industrial automation, PLC programming, crane automation, and control cabinet building.

As the company continued to enjoy growth, existing production processes became increasingly entrenched. Processes that had evolved over the years proved not to be the optimum solution in all areas. At the same time, the existing production area posed an additional challenge. Limited space resulted in restricted movement areas, inefficient walking routes, and difficult access to materials and work areas. The goal, therefore, was to make production more efficient without necessarily having to make major investments. Instead, the focus was on analyzing existing processes and identifying opportunities for optimization in the organization, material flow, and workstation design.

The starting point was a lean workshop designed to identify the impact of organizational changes on production times. On this basis, actual material flows and work processes were analyzed, and opportunities for improvement were identified. An important step was the subsequent reorganization of the production area: the receiving area, temporary warehouse, and mechanical processing area were rearranged to shorten travel distances, improve processes, and reduce disturbances including noise.
At the same time, the workstation design was further developed in collaboration with the employees. Using cardboard engineering, prototypes were created, tested in everyday work situations, and then implemented. This resulted in ergonomically designed wiring carts with material provision and structured conductor routing directly at the workstation. Employees were involved throughout the entire course of the project. This resulted in practical solutions that work in everyday life and that can be sustainably developed further.