Curbed‘Roofing’Manpower Dependence
Accelerated Production line
Setting TheScene
Keystone Lintel Limited, a leading manufacturer of steel lintels and roofingsolutions. At their Derbyshire facility, theyproducea wide range oflintelvariationsfrom high grade pre–galvanised mild steel with a zinc coating of 600g/m².With an extensive productline-upand alabour-intensivemanufacturing process, the company faced challenges in terms ofmanpowerrequirements and energy consumption.
Optimised Operators Headcount per Line
Reduced Energy Consumption by Eliminating Welding
Elimination of Rework & Re-galvanising
Minimised Total Cost of Operations
TheChallenge
Keystone Lintels produced 122 variations of lintels,with length varying from 750mm to 4.8m, material thickness from 1.6mm to 3.2mm, 3 cavity widths, 2 outer leaf lengths and 132different typesof insulation.
It required multiple production lines and extensive manual labour. This process involved shaping the lintels using press brakes and performing insulation fitting, welding, and galvanised painting. The existing production method demanded significantmanpowerand consumed substantial energy, hindering operational efficiency.
TheSolution
To address these challenges, a semi-automated production line was developed, integrated with the existing automated press brake folding line. The new production line featured an insulation loading station, guided by screens that directed operators on insulation placement.
Two insulation presses ensured precise positioning of insulation within the lintel cavity. A break plate punch system transformed a steel coil into individual plates, which were then stacked and transported by a conveyor system to a pick and plate cell.
This cell picked the plates, performed necessary punching, and pierced the insulation in the lintel. The lintels continued through a roll forming station for perforations and outer lip formation before reaching the end of the line for operator offloading.
TheBenefits
The new production line achieved remarkable outcomes for Keystone Lintels. With a production rate of 4.8 meters of lintels every 27 seconds, the line had the capacity to produce 6,665 lintels and 21,300 break plates in a 10-hour shift. The significant reduction in manual labourrequiredto produce a single lintel was a key benefit, streamlining operations and improving overall efficiency.
The adoption of clinching technologyeliminatedthe need for spot welding, reducing energy consumption andeliminatingthe necessity for post-galvanized coating. This resulted in cost savings and an improved workplace environment.
Optimised Operators Headcount per Line
Reduced Energy Consumption by Eliminating Welding
Elimination of Rework & Re-galvanising
Minimised Total Cost of Operations
Ask About OurBespoke Robotic Solutions
Our extensive design office has generations of knowledge in providing innovative material handling systems. From our sales engineers, to our fabricators and installation crews, we have a team who cares about your projects as much as you do!
Please contact us to see how we can help increase your productivity.
如果你想知道a bit more detail about this project then please let us know and we will be happy to arrange, in the meantime enter your email to download the shortform PDF.
