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WiN woodworking INTERNATIONAL 2021/4

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We report on all aspects of woodworking from board materials, wood treatment to machines, tools and technical know-how, from timber engineering supplies to the latest developments in technologies and markets. We address factory managers and production engineers directly, and thus ensure coverage of the decision makers within the industry. Circulation is worldwide with special emphasis on the most important growing markets. An increasing share are subscriptions and requested copies. Our online-section will further be expanded according to reader requests. WIN – woodworking INTERNATIONAL is published in English.

USER REPORT Fully

USER REPORT Fully networked Do you think limited installation space rules out optimised performance? Absolutely not! IMA Schelling demonstrated that once again with a project for the Dutch kitchen manufacturer DKG. The German-Austrian plant constructor recently designed a new highly productive, fully networked batch-size-1 system where the remnants storage area was moved to the first floor above the cutting area to save space. The system went into operation in January 2021. One of two integrated area storage systems of type v16 Image: IMA Schelling The De Keuken Groep (DKG), with its two high-end kitchen brands BRUYNZEEL Keukens and KELLER Keukens, operates one of Europe’s largest and most cutting-edge kitchen factories at the Bergen op Zoom (NL) location. In the fully automated and fully networked plant, around 240 employees produce 500 kitchens and 25,000 cupboard parts every day in 150 styles and in any dimension specified by the customer. DKG’s operations are CO 2 -neutral thanks to its own thermal power plant in which production waste is burned, and a photovoltaic system that provides the majority of the required energy. “In recent years we’ve enjoyed particularly strong growth in the private market, with demand for custom kitchens increasing noticeably. However, there is also growing demand for custom-made kitchens in the project segment, for example in the furnishing of entire apartment units,” explains Ad van den Hoek, Senior Project Manager at DKG. It was therefore vital to expand production capacity in Bergen op Zoom, especially in the batch-size-1 area. Challenge: restricted space, high expectations There were two central requirements when designing the new system: the new components would have to be integrated into the existing production hall and be networked with the current warehouse, cutting and edge banding solutions to achieve fully automated manufacturing. However, those weren’t the only challenges. “DKG also sets the bar very high when it comes to quality, machinery performance and availability. The requirements specifications are particularly extensive. However, DKG is fully aware of that,” explains Martin Papst, the project manager in charge at IMA Schelling. “Our kitchens are top class and our customers have very high expectations,” adds Ad van den Hoek. “So we can’t simply buy a machine and get started. “Rather, with these kinds of investments we enter into a ‘marriage’ with our suppliers – with clear guidelines for maintenance, inspection, fault repair, replacement parts inventory and training, which both sides must comply with.” This concept seems to work. As does the ‘marriage’ with IMA Schelling, because this is now the fourth IMA Schelling system since 2007 that DKG has invested in. “The collaboration with IMA Schelling has proved a successful one. Our designers work closely with the IMA Schelling project team, and the joint engineering results in successful solutions,” explains Ad van den Hoek. To make it possible to integrate the new system into the existing production facilities, DKG optimised its raw panel shelf warehouse beforehand, which is now operated using a Hubtex sideloader. 600 m 2 of usable space was saved this way. However, the installation was still very precise work. “Space was really at a premium. And it wasn’t simply a case of making sure the machine fitted into place. We also had to bear in mind access for servicing and maintenance,” says Martin Papst. The machine layout developed by IMA Schelling was correspondingly compact. The system, which allows remnants to be precommissioned overnight and without an operator, has boosted the factory’s total output by around 20,000 units per week or around 1,500 units per shift. This also created additional storage capacity for around 1,500 large remnants. Special feature: remnants storage above the cutting area Space-saving special feature: remnant storage above the cut-to-size area Image: IMA Schelling The existing IMA Schelling systems include two area storage systems with one and two gantry cranes, respectively. They operate a fully automated ah 6 angular system for the batch-size-1 cutting of laser fronts and a second ah 6 for series cutting and the new ls 1 for bodies and fronts. There is a level-access remnants storage area with gantry 24 No. 4 • October 2021

USER REPORT Everything interconnected “The expansion and complete networking of all system components has made us far more flexible and we can now distribute production over all systems,” explains Ad van den Hoek. Should one saw or storage system malfunction, the other machines can take over. For example, if the emergency stop is triggered on the area storage system, the batch-size-1 saw is supplied with panels from an external feed-in (chain conveyor) – all controlled automatically by the warehouse software of the remnants storage system. Depending on the cutting plan mix, the output of the panel cutting saw ls 1 for industrial batch size 1 averages 1500 parts per shift Image: IMA Schelling crane for the remnants of the two angular systems. The usable panel remnants from the new batchsize-1 saw all go into the remnants storage area located above. All cutting solutions and storage areas are fully networked, guaranteeing maximum flexibility. A third manual saw of the fh 4 type by IMA Schelling is also integrated into this network. The new fully automated, fully networked batch-size-1 system consists of a batch-size-1 cutting machine (ls 1) with a remnants storage area 30 x 16 meters in size (vs 16) installed above it and a Combima edge finishing machine with upstream computing buffer and the required transport and handling features. With the new one-sided edge circulation, which replaces an older edge banding machine by a competitor, body parts undergo laser edging with EVA hot melt adhesive and fronts (melamine and high gloss) in four runs. onto a roller conveyor. There, a vacuum lifting device lifts the panel remnants and stores them in the remnants storage area. If remnants have to be supplied to the cutting machine, the vacuum lifting device takes these from storage and places them in front of the lifting tower, which then supplies the ls 1. Remnants that are no longer required can be cut by the ls 1 into waste and thrown into the vibration chute via a waste flap like the other cutting remnants. The waste then passes through a cutting machine and hacker on its way to the in-house thermal power station. Jobs are generated and assigned predominantly on a daily and weekly basis. DKG chooses the batch-size-1 manufacturing line for processing when fewer than 50 of the same body parts or fewer than 30 identical front parts accumulate in one week. Anything above that goes into series production and is cut on the ah 6 angular systems in packages. However, DKG changes the threshold of 50 and 30 as it sees fit in order to put together practical manufacturing orders and manage production efficiently. DKG is currently testing ZIMBA, IMA Schelling’s IIoT and service platform, for OEE analysis (OEE = Overall Equipment Effectiveness). “The trial version is, of course, not fully adapted to our requirements. But a certain period of time is enough to tell whether we’d benefit from ZIMBA. We are very excited,” says Ad van den Hoek. www.imaschelling.com The ls 1 saw receives its single panels from the existing double-gantry area storage system. Because of the two cranes, the 60 x 16-meter storage area is able to serve two cutting machines – the ls 1 and an ah 6 – at the same time. The supply conveyor starts in the area storage system at a height of 2,000 millimetres. Right next to the storage area, a lifting table raises the single panels that are to be conveyed to a height of approx. 3,200 millimetres, at which the rest of the conveyor line runs. The difference in height between the conveyor line and the saw is overcome by a lifting tower that transports a panel for lateral loading onto the ls 1 every 35 seconds. The usable remnants from the batch-size-1 cutting machine are placed, via a circulation trolley, on a brush conveyor that transports them DKG produces 500 kitchens and 25,000 cupboard parts every day in 150 styles and in any dimension specified by the customer with around 240 employees - and does so in a CO 2 -neutral way Image: DKG No. 4 • October 2021 25

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