The packer handles more than 100 washbasins in one shift – in eight hours – with the vacuum tube lifters.∼ Andreas Lotz, Head of Finishing at Duravit AG in Hornberg
Duravit Relies on Ergonomic Vacuum Lifters From Schmalz
Duravit, a leading manufacturer of individual bathrooms and sanitary ceramics, not only attaches great importance to aesthetic perfection, but also to the health and well-being of its employees in production. With this in mind, the company has implemented an innovative solution to reduce the ergonomic strain involved in packaging the heavy ceramic washbasins. The use of vacuum tube lifters from Schmalz not only minimizes physically strenuous activities, but also reduces the risk of illness-related absences. This measure is part of a holistic approach to optimizing work processes and increasing employee satisfaction.
Features of the success story
| Industry | Sanitary ceramics |
|---|---|
| Workpiece | Washbasins |
| Product group | Vacuum Tube Lifter JumboFlex |
| Type of handling | Manual Handling |
With Schmalz
50
kilogram
effortless handling
100
washbasins
per shift
The customer: Duravit AG
Duravit AG is a leading manufacture of high-quality sanitary products based in Hornberg, Germany. The company produces a wide pallet of sanitary ceramics, including washbasins. Duravit is known for innovative design, high quality and sustainable production. Duravit is present in over 130 countries worldwide and employs round 6,200 employees, 600 of whom work at the headquarters in Hornberg.
The challenge
Duravit manufactures round 250 models of ceramic washbasins in different variants, which can vary considerably in size and shape. In order to package them ready for dispatch, an employee guides the washbasins, which are stacked on pallets and sorted by type, individually on a pallet truck into the packaging area. Previously, two employees were on hand here to manually remove the large washbasins, weighing between 20 and 35 kilograms, from the pallet without any aids, pack them in cardboard boxes and place them on a pallet for further transport. In this way, the employees had often lifted more than three tons after one shift. Those responsible at Duravit recognized the need for action and focused on designing the work processes as ergonomically as possible.
The solution from Schmalz
Duravit uses a solution from Schmalz consisting of two components: vacuum tube lifters from the JumboFlex 50 series and an aluminum crane system. The vacuum tube lifters enable employees to move loads weighing up to 50 kilograms ergonomically and at a high cycle frequency. The JumboFlex 50 vacuum tube lifters are equipped with a central two-finger control that allows employees to lift, lower and transport loads effortlessly. Thanks to a quick-change system, the vacuum suction cups can be easily exchanged depending on the shape of the workpiece to be handled, with Duravit using three different gripper options to ensure optimum adaptation to the surface finish and geometry of the washbasins. An aluminum crane system was installed to support the vacuum tube lifters and ensure efficient handling of the washbasins. With a working area of 13 x 4 meters, the crane system offers sufficient space for moving the loads. By using aluminum as the construction material, it was possible to reduce the weight of the crane system, which leads to improved responsiveness and enables fatigue-free working. In addition, the vacuum generator was integrated into a soundproof cabin to reduce the noise level and protect the vacuum pump from outside contamination. This integrated solution from Schmalz helps to overcome the ergonomic challenges in Duravit's packaging process, reduce the physical strain on employees and increase efficiency.
Instead of two employees, only one is now responsible for packaging the washbasins.
Ready for storage: the JumboFlex vacuum tube lifter lifts the large cardboard boxes from the roller conveyor onto the pallet.
Optimum system: easy-running aluminum crane plus ergonomic vacuum tube lifter.
Customer benefits through the Schmalz solution
Ergonomic work processesProtecting the health of employees by reducing physically strenuous activities
Increased efficiencyHigher productivity through the use of vacuum tube lifters and aluminum crane system
Reduction in absences due to illnessFewer cases of illness thanks to ergonomically designed work equipment
Optimal working conditionsIncrease in employee motivation
Products used in the application
Vacuum Tube Lifters JumboFlex Generation 1
- JumboFlex for ergonomic one-hand operation for fast movement sequences
- Configurable lifting unit, operator handle, vacuum gripper and vacuum generator
- One-finger / two-finger control for right-handed and left-handed users
- For workpieces up to 50 kg