Assembly line reduces strain on employees and increases productivity

Task

Flexible and ergonomic processing of mechanical modules

A manufacturer of security components wants to reduce strain on its assembly staff and increase productivity at the same time. It is therefore seeking a new, more efficient assembly line with three workstations for mechanical modules.

The idea: Employees should not have to lift and transport the modules, which is strenuous and could even lead to injuries. Instead, the product should adapt to the worker’s movements and remain flowing between the individual stations.

The line should also be able to adapt quickly to different body sizes to enable ergonomic posture. Flexibility and adaptability to different products are also required to ensure that the system is future-proof.

Solution from mk

Height-adjustable assembly line with roller conveyor and rotating pallets 

The experts at mk developed a five-meter-long assembly line from Series 40 aluminium profiles (40 mm grid) with electric height adjustment. It can be easily adjusted to different body sizes. An RBS-P 2066 gravity roller conveyor with a roller diameter of 40 mm extends across the entire width of the table top. The roller conveyor transports pallets on which the employees can place the mechanical modules and move them effortlessly from one processing station to the next.

At the individual stations, employees can secure the pallet with an index bolt so that it does not slip or wobble during work. The pallet is also divided into two parts so that the product can be worked on from all sides. The top can be rotated in 180-degree increments. The provision of material is accomplished with bin racks at the rear of the line. Above the workstations, the assembly line is equipped with a riser containing tool gliders and LED lighting. A supply rail is integrated for suppling compressed air to the tools.

Benefits for the customer

• Reduced strain on employees: Ergonomic and height-adjustable assembly stations ensure better productivity and lower risk of injury.
• Custom design: By working closely with mk, the customer received a customised assembly line made according to its exact specifications.
• Flexibility: The assembly stations can be easily adapted to changing products.

Products use

> Series 40 aluminium profiles
> RBS-P 2066 roller conveyor