In this case study we will show you how MBFZ toolcraft GmbH used the production workshop simulation software, Visual Components to develop a robotic system for automated assembly for a bathroom furniture manufacturer and create the first “batch size 1” production plant .
Key benefits:
- Increased production throughput without sacrificing quality
- Automation of monotonous tasks
- Feasibility analysis and optimized cycle times quantify economic benefits
The first production line for “Batch Size 1” in the furniture industry
Today's typical customer wants individual products on the one hand, but low prices on the other. However, these two goals seem to contradict each other: The diversity of customer wishes leads to high product variability and thus to increasing production complexity. However, there is a solution – personalized mass production or mass customization .
The trend toward personalized mass production is not only evident in the automotive industry, where customers have long had countless options to choose from, but also in the furniture market. This is particularly true for bathroom furniture, which often must be installed in a narrowly defined space and where a wide range of dimensions, colors and surfaces are offered. Furthermore, further complexity is added by the technical conditions, i.e. the number, shape and size of sinks and the number and design of siphons.
Most furniture manufacturers would be overwhelmed by the task of converting their operations or production facilities into custom mass production on their own . But fortunately there are specialists for such tasks, such as the company MBFZ toolcraft GmbH from Georgensgmünd in southern Germany. The company is a pioneer in cutting-edge technologies such as turnkey individual robotic solutions . MBFZ toolcraft GmbH, which has received several awards for excellence, was only founded in 1989 and today employs around 400 people. Additionally, its customers include market leaders from the semiconductor industry, aerospace, medical technology, optical industry, special machinery as well as motorsport and automotive.
Required by customer: Production with “batch size 1”
To meet market demands for tailor-made mass production, a renowned manufacturer of bathroom furniture asked MBFZ toolcraft GmbH to develop a robot system for the automated assembly of drawers for bathroom furniture. Therefore, the drawers, with or without siphon, had to be of different sizes, from the smallest drawer with 170 mm to the largest with 1450 mm.
The furniture manufacturer also required the production of a wide range of variants with individual selection of materials and colors with “batch size 1” ; i.e. it should be possible to produce each piece of furniture as a tailor-made product if necessary. With modern production technology, even batch size 1 can be profitable for the manufacturer and affordable for the customer.
Before automation, drawer assembly was done manually with hand tools; the drawer frames were pressed to the floor using a pneumatic press. The new factory was designed to allow two-shift production; it was about facilitating manual processes and automating monotonous activities .
The production line was planned entirely virtually with production shop simulation software, Visual Components
Following the client's request, a feasibility study and visualization were carried out during the concept phase. For this purpose, MBFZ toolcraft GmbH used the factory planning and simulation software from Visual Components . With Visual Components, the company uses an ideal system, because with Finnish company's 3D factory simulation software design, simulate, optimize and validate customized production systems.
In the newly designed system, component data is recorded and processed by a scanner after being placed on a conveyor belt. A robot feeds the individual components to an automatic assembly station where they are screwed or pressed together. Next, the fully assembled drawers are placed on a conveyor belt by the robot and transported to a station where they are manually removed and picked or stored.
The particularity of this project: This is the first “batch size 1” production factory in furniture manufacturing . Therefore, the planning, implementation and construction of the factory took approximately one year and three months.
Visual Components Factory Components Library Makes Planning Easy
One of the challenges was that the assembly line requires sensor technology and complex monitoring, as components must be positioned in precise relationship to each other. To ensure full flexibility, it was necessary to implement the handling of all component variants with a single flexible gripping system . Additionally, a fully automated assembly press had to be developed and integrated into the production line.
The starting point when planning such a system is usually a 2D plan. Based on this layout, factory components such as conveyor system, assembly press, robot and grippers are assembled to form a production line. MBFZ toolcraft GmbH used the library provided by Visual Components ; if a specific machine was not available in the library, it was created from an existing CAD model and inserted into the library. Visual Components has interfaces to all major CAD systems.
3D simulation facilitates production line design
Visual Components solutions played a key role in the success of the project . First, the entire factory was staked out and visualized virtually. The virtual model was used to ensure the basic feasibility of the concept requested by the client.
The exact dimensions of factory components are stored in the library of the production shop simulation software, Visual Components. This made it possible to carry out very simple tests on the virtual model to determine the range of the robot and the accessibility of all work areas. Finally, it facilitated the positioning of the assembly press, robot and conveyors.
Production cycle times have been optimized with production workshop simulation software
The Visual Components library also contains other important attributes, such as robot motion parameters , which can be used to perform accurate time and motion simulations . As a result, the entire system could be optimized by determining the minimum possible cycle times on the virtual model. In doing so, the company was able to prove the economic benefit of the system for the customer.
Thanks to Visual Components, it was not only possible to determine the technical feasibility and quantify the economic benefit; The model created with Visual Components also made it much easier to illustrate the system and production sequence to the responsible employee at the customer, the furniture manufacturer.
Visualization with Visual Components illustrates even complex systems
“We use Visual Components solutions in our company for all projects that require visualization and feasibility analysis. »
MBFZ toolcraft GmbH particularly appreciates the fact that process steps, even for complex systems, can be easily visualized and presented to “non-technical people”.
“Budgeting and pricing are also significantly simplified because we can configure the entire system digitally beforehand.
» “We also plan to use Visual Components to simulate processes in other areas of manufacturing expertise, e.g.
additive manufacturing and machining, mold making and plastic injection molding as well as automated quality control. »
A win-win situation for all
As a result, MBFZ toolcraft GmbH and Visual Components helped the bathroom furniture manufacturer fulfill its customers' wishes for individual, yet affordable products. As a pleasant side effect, it can be noted that the production throughput could be increased while maintaining the same quality, and that many monotonous tasks are now carried out by robots – a win-win situation for all stakeholders!
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