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Layout planning and workstation design
Digitally supported and ergonomic workstations form the basis for efficient processes in the newly designed control cabinet production at Tobol. Together with Phoenix Contact, the entire area was planned according to value and material flows and individual workstation solutions were developed with employees.
Since 1997, Tobol has been synonymous with tailor-made solutions in the field of MCR automation for computer centers and buildings. The focus is on applications for air conditioning, ventilation, energy, and monitoring. In addition, switchgear of exceptionally high quality is manufactured at the high-tech location in Leinefelde, Germany.
In addition to the main location in Leinefelde, Tobol coordinates large-scale national and international projects from its subsidiaries in Frankfurt am Main and Berlin, Germany. Every day, 80 employees ensure reliable high quality of the planning, setup, and design work for a prestigious customer base throughout Europe.
The challenge
Tobol had started construction of a new large production building for control cabinet production. The company contacted and worked together with Phoenix Contact to increase the efficiency of its internal production processes. In addition, the focus was on improving the working conditions for employees. Other objectives included reducing project lead times and the consistent digitalization of processes.
The solution
At the start of the project, a quick check of the current situation was first carried out in the factory. A detailed material and value stream analysis followed on from a common objectives workshop. Based on these results, the entire layout of the new production hall was planned and individual workstation solutions developed together with employees according to lean production methods. To this end, prototypes of the workstations in cardboard engineering were first developed. After a successful test phase, the workstations were then implemented. In addition, shop floor management was introduced for daily regular communication and for the continuous improvement process within production. To ensure long-term results, two employees took part in the Phoenix Contact expert training course on “Lean production, workstation design, and digitalization”.
The partnership with Phoenix Contact helped us to optimize our digital processes, material paths, as well as workstations and workflows. This enabled us to future-proof our production while establishing sustainable practices.
Successful collaboration for more efficient processes
Conclusion
Results of layout planning and workstation design
Production planned according to value and material flows reduces walking distances and transport paths. The tailor-made workstations reduce reaching distances and search times. At the same time, they increase employee satisfaction and well-being. Sustainable results were achieved through the introduction of shop floor management and training courses in the expert program.
Detailed 3D layout planning for optimized material paths and walking distances
Software-supported workstation for terminal strip production with pick-by-light system
Direct control of the THERMOMARK E.VARIO for marking complete terminal strips
Individual wiring workstations based on lean production methods
Central marking station: Control of all devices via the MARKING system software
Improved regular communication with daily shop floor management
Individual workstation design with cardboard engineering
Individual material trolleys for material provision
Jointly developed test location
A partnership of equals
Increased productivity Production planned according to value and material flows reduces walking distances and transport paths. The tailor-made workstations reduce reaching distances and search times.
Decoupled terminal strip design The workstation solution that was developed, including the worker assistance software, provides quick and easy guidance through the entire terminal strip production process. Intuitive software support enables the use of semi-skilled workers.
Reduced production times With the centralization of terminal strip production, the search, running, and idle times were significantly reduced.
Improved ergonomics The ergonomically optimized workstations ease the workload of employees in many ways, e.g., through short reaching distances.
Continuous improvement process Sustainable results were achieved through the introduction of shop floor management and training courses in the expert program. This also ensures ongoing optimization.
Shaping processes together
Process optimization along the value chain
From engineering to production – our partnership approach provides you with custom consulting services to optimize your process chain in control cabinet building, based on practical lean production methods. The consulting services are based on years of experience with the methods and include a comprehensive range of consulting activities and training programs for employees.
