Plant optimization, Assembly service, Logistics concepts

In UV printing, the ink does not dry in the ambient air – as on a sheet of paper, for example – but is cured directly after application to the surface of the substrate with ultraviolet light. This printing process is suitable for almost all materials and applications and enables very high production speeds of 22 m2 per hour on average. The manufacturer of UV systems for the label and narrow web printing industry uses fans to remove the heat generated by the UV lamps when the ink cures.

First, three fan units with different impeller types previously used by the customer were extensively analyzed in the punker laboratory in Eckernförde to identify potential for optimization. Performance measurements on the punker chamber test bench showed to what extent the system efficiency of the affected units must be increased in order to meet the energy efficiency requirements of ErP. After the subsequent examination of the units in the reverberation chamber, the optimum impellers from the punker portfolio were selected or developed and a suitable housing geometry was determined in order to achieve the targets.

The analysis and optimization of existing systems and the development of new ventilation solutions have been punkers’ strength for decades. In this project, the challenge for us was to develop a completely new assembly service process. The approach was to realize all steps from the adaptation of the motor cabling and the mechanical assembly of the unit to the test run in a one-piece-flow by only one single employee. Material is supplied by rolling logistics according to the supermarket principle, the delivery to the customer according to the pull principle. In order to implement this process smoothly, suppliers must be closely involved in our logistics processes.

The “Assembly Service” workstation has been designed to ensure a high degree of flexibility for the assembly of variants. Standardized assembly steps with material and tool feeding in the BestPoint ensure ergonomic workplace design, the simultaneous reduction of lead time and material stocks (WIP) leads to minimum space requirements and short walks in assembly. The varied and at the same time responsible work at this workplace places special demands on the qualification and awareness of the assembly personnel. The employee in the assembly service process personally labels and signs their plug-in unit and thus assumes responsibility for delivery quality at the customer’s facility.