PRODUCTS & SERVICES
The importance of ergonomics in commercial vehicle production
One hundred and twenty-seven crane bridges, as well as a wide variety of hoist units, manipulators and power screwdrivers, integrated into more than six kilometres of rails in four profile section sizes – that was the scope of the KBK Aluline system that an international Demag project team planned and installed recently. This extremely smooth-running system improves ergonomics for handling parts and is a key factor for optimised productivity throughout the entire vehicle assembly operation. The Volkswagen AG Polish plant was to manufacture the latest generation of its VW Crafter where more than 3,000 employees manufacture the vehicle and – in the integrated supplier park – many third-party components. The plant, which covers 220 hectares, is designed for an annual capacity of 100,000 light commercial vehicles and has generous workshops for the body line and vehicle assembly as well as a state-of-the-art paint line. Heavier parts than in car production On vehicles such as the Crafter, everything is slightly heavier and larger than in a car production line. For this reason, the handling of parts plays a much larger role. Since commercial vehicles are usually made in lower quantities than car volume models, but in larger numbers of variants, many steps in production cannot be fully automated. Due to the weight of the parts, many stations need to be served by manipulators, workplace 16
Lifting Africa - May/Jun 2020
cranes and other handling equipment. This applies throughout the entire final assembly process, which is divided up into seven production and pre-assembly sections. Parts for a number of variants are also sequenced, picked and staged in several “supermarkets”.
Demag KBK Aluline Provides Full Coverage Volkswagen’s planners decided in favour of Demag KBK Aluline as a universal system to be used throughout the assembly operation.
Assembly of the VW crafter is implemented in 155 takt cycles. Components are continuously retrieved from load carriers, lifted or assembled into orders, which requires the use of corresponding lifting and transport equipment to provide the best possible ergonomics for the workers at the individual workplaces. Emil Berning, Managing Director, Konecranes and Demag (Pty) Ltd, said “The well-being of workers in large plant environments is an important factor that we at Demag pay close attention to. Our machines have been ergonomically designed in order to ensure ergonomics on the factory floor enhance the worker’s plant experience while maintaining the highest level of safety throughout the production and assembly processes”.
The Demag KBK Aluline crane construction kit has delivered an optimum performance in the entire automotive industry for more than five decades all over the world. The Demag brand aluminium crane construction kit offers particularly smooth running characteristics and low rolling resistance. In combination with its light-weight design, these properties offer direct benefits to
