[Case Study] Achieving Reduction in Man-Hours and Improvement in Quality in the Bending Process

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last updated：Feb 17, 2021

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Introduction of a case where labor reduction and quality improvement in the bending process were achieved beyond the introduction of robots!

Company B, which undertakes sheet metal processing from various industries, owns about 10 press brakes and was handling bending processes using a manpower-intensive approach. To automate the bending process and reduce the burden on each worker while reallocating them to other processes, a robotic automatic bending system was introduced. While this contributed to some degree of burden reduction across the entire bending process, it also led to new challenges. In response, a "panel bender" was introduced. Now, even those who are not skilled workers can perform hemming bends and R bends, and even complex bends that are difficult for skilled workers can be achieved by simply setting the material, allowing for high-quality bends to be repeated. As a result, product quality improved, and waste due to quality defects caused by worker negligence was reduced to zero, leading to a decrease in losses from reworking materials. [Case Overview] - Industry: Sheet metal processing - Product Shape: Panel shape - Material Thickness: Mainly soft steel under 1.0mm - Production Volume: 1 piece per lot *For more details, please refer to the related link page or feel free to contact us.

Related Link - https://panelbender.salvagnini.co.jp/20201123-2/

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【Introduction Effects】 ■ Although it is not completely unmanned and operators are involved, these operators do not need to be skilled workers; they can be part-time or foreign workers. As a result, traditional skilled workers can be reassigned to higher value-added bending processes or other operations, leading to overall efficiency improvements in the process. ■ Even those who are not skilled workers can perform hemming bends, R bends, and even bends that are difficult for skilled workers, simply by setting the materials, allowing for high-quality bends to be produced repeatedly. ■ Product quality has improved, and there is zero waste due to quality defects caused by operator negligence that occurred with manual brakes, resulting in reduced losses from reworking materials. ■ Processing time has become very fast, eliminating the need for material setups and changeovers, which has reduced horizontal handling tasks. As a result, the entire bending process, which previously required long working hours, can now be completed within a fixed time. *For more details, please refer to the related link page or feel free to contact us.