However, plant construction and programming were comparable to smaller plants. A complete movement profile of the robot was simulated by Roboguide. “Accessibility for manual operations was a big issue in the design process,” says Egli. However, to prevent “cold deformation” of the safety guard, robot specialists at Robofact devoted themselves to the topic of “safety” very intensively. The cubicle is protected by light barriers and a floor scanner. A white light indicates to the employees that access to the work area is free. “With our chosen solution, we can use our staff much more efficiently,” concludes Brülisauer. “We have become faster and more efficient.” Just with the introduction of a double-strand system, higher production capacities were created. In addition, the throughput in the extrusion section has been significantly boosted with the new equipment. However, the robot speed is limited to 60% after the initial trials at maximum speed as the handling times are hardly reflected in the cycle time anyway.
Total automation has also reduced personnel expenses. The savings potential lies mainly with shorter lengths, because here the share of manual operations is greater.
The amortisation will take three to four years. One thing is already clear: “With the entire plant, we were able to take a big step forward in the development of this production,” says Manuel Frei. Above all, this concerns the plant's production capacity and efficiency. “The right products, efficient equipment, high quality and proximity to the market” are the building blocks of success for Brülisauer."