The user-friendly solution is easy to operate. Schmalz created custom solutions from proven designs. We appreciate the well-thought-out design that makes daily operations straightforward and efficient.∼ Barry Hulshof, Process Engineer at 247TailorSteel
247TailorSteel boosts productivity with Schmalz Vacuum Solutions
247TailorSteel, a leading sheet metal processing company, faced ergonomic challenges when handling heavy metal sheets weighing up to 200 kg. The manual material handling process from laser cutting to edge finishing was physically demanding and limiting productivity. Schmalz delivered automated AI vision based machine loading solutions and custom-made vacuum lifting devices that transformed their operations. The result: safer handling, reduced operator strain, and increased efficiency across all production steps.
Rysy úspěšného příběhu
| Průmysl | Metal |
|---|---|
| Obrobek | Sheet metal |
| Skupina výrobků | Vacuum Tube Lifter JumboErgo Vacuum Tube Lifter JumboFlex Solution Kits ivOS Sheet Metal |
| Typ manipulace | Manual Handling Automated handling |
Se společností Schmalz
25
percent
more productivity
30
percent
less labor costs
Zákazník: 247TailorSteel
247TailorSteel is a sheet metal processing company specialising in laser cutting, bending and tube cutting. It is based in the Netherlands and employs around 1,000 people. The company operates in the sectors of sheet metal laser cutting, bending and tube cutting. It handles metal plates with maximum dimensions of 3,000 x 1,500 x 25 mm and weights of up to 200 kg. 247TailorSteel combines advanced laser cutting technology with precision bending and finishing operations to meet the exact requirements of its industrial customers. Their expertise spans from initial cutting operations to complex finishing processes, for which reliable material handling solutions are required throughout the entire production workflow.
Výzva
247TailorSteel processes large metal plates in multiple production steps, including laser cutting, palletised material handling, bending operations, tube cutting and edge finishing. Each plate weighs up to 200 kg and has maximum dimensions of 3,000 x 1,500 mm. Previously, operators had to manually transport cut parts between machines and workstations. This manual handling of heavy plates has placed significant strain on employees. The repeated lifting of materials weighing up to 200 kg contributed to workplace fatigue and increased sick leave rates. Moreover in the edge finishing process in particular, substantial manual labour was required to transport parts from pallets to automated machines, which limited production efficiency and increased operational costs. Therefore, 247TailorSteel needed a safe method of handling heavy and large parts that would not compromise workflow speed. Specifically for the edge finishing process, the company sought to reduce labour costs while maintaining process stability. The solution had to be userfriendly and straightforward to operate, minimising training requirements and enabling seamless integration into existing processes.
Řešení od společnosti Schmalz
To address 247TailorSteel's challenges in heavy material handling and edge finishing efficiency, Schmalz implemented an innovative automated solution combining Solution Kits ivOS Sheet Metal for automated machine loading with different manual vacuum lifting systems. Central to this solution are Schmalz's vacuum lifting systems including the Vacuum Tube Lifter JumboErgo, Vacuum Tube Lifter JumboFlex and a customized Vacuum Lifting Device VacuMaster Comfort, specifically engineered for 247TailorSteel's demanding requirements. The system safely allows lifting metal plates weighing up to 200 kg with smooth, oily surfaces, seamlessly moving materials between production stations – from laser cutting through bending and tube cutting operations to edge finishing. The vacuum lifting devices provide ergonomic handling, significantly reducing physical strain on operators while maintaining consistent cycle times throughout the production workflow. This application has been enhanced with the Solution Kit ivOS Sheet metal, an AI-powered solution for automated machine loading. The vision system recognizes workpieces in various sizes and shapes without CAD-matching, while the software operates robots and individually controls the suction cups of the vacuum gripper. This integrated approach automatically manages cut metal plates from pallets to edge finishing machines, enabling a single operator to supervise multiple finishing stations simultaneously while eliminating manual transport steps and drastically reducing labor costs. By automating the edge finishing process, Schmalz has enabled 247TailorSteel to achieve safer working conditions, lower operational costs, and sustained production stability without compromising workflow speed or requiring extensive operator training. The solution integrates seamlessly into existing processes, delivering immediate benefits and positioning the company for sustainable, efficient growth.
Výhody pro zákazníky díky řešení Schmalz
Reduced operating costsWith our solutions 247TailorSteel reduced edge finishing costs while maintaining quality standards.
Increased employee satisfactionEmployee satisfaction increased significantly due to reduced physical demands.
Complete Solution ProviderThe manual and automated solutions from Schmalz enable customers to scale from ergonomic support to complete automation.
Produkty použité v aplikaci
Vacuum Tube Lifters JumboErgo
- Tube lifter JumboErgo for dynamic handling of flat workpieces
- Configurable lifting unit, operator handle, vacuum gripper and vacuum generator
- Workpieces can be swiveled by 90° (optional with JumboErgo PSE)
- Workpieces up to 300 kg
Vacuum Tube Lifters JumboFlex
- JumboFlex for ergonomic one-hand operation for fast movement sequences
- Configurable lifting unit, operator handle, vacuum gripper and vacuum generator
- Intuitive two-button control for up/down control, also available with proven one-button control on request
- For workpieces up to 50 kg