Fixture construction: assembly, lifting, turning, testing, transport fixtures & more

FAQ FIXTURE CONSTRUCTION - WHAT TO CONSIDER? OUR KNOW-HOW FOR INTEGRATED PROCESSES

In many industrial applications, standard workstations or simple devices are not sufficient to carry out complex assembly or other work steps safely and efficiently.

But what needs to be considered during development and production?

Particularly with heavy, sensitive or high-priced products, requirements arise that can only be mastered with customer-specific devices. As central interfaces in the production process, fixtures for assembly and work processes are crucial for quality, ergonomics and efficiency.

We are therefore focusing on increased productivity:

• Holistic process view
• One device solves several tasks and speeds up all work processes
• Technically clean design of heavy and complex products
• Integration into current production environments
• Close cooperation from analysis to acceptance

 
The result: tailor-made fixture solutions that stabilize and improve processes in the long term, making them faster and more productive.

EQUIPMENT WITH A HEAD START - THROUGH INTEGRATED PROJECT PLANNING

We develop and build integrated fixture solutions for assembly and work processes - wherever a special solution is required. We support our customers from process analysis and technical design through to implementation, testing and acceptance.

The challenge lies not in the individual work step, but in the process as a whole:

• How does the product get to the workplace?
• How is it picked up, positioned and secured?
• What work steps take place before and after?
• What safety, ergonomic and quality requirements must be met?

Our focus is therefore on process-reliable solutions, clear technical responsibility and integration into existing production environments.

WHAT SHOULD BE CLARIFIED BEFORE BUILDING THE FIXTURE

We provide the right answers to the crucial questions.

Product feed & intake

• How is the product delivered to the workstation? Manually, by hoist or via transport and transfer systems?
• Does the product need to be aligned or moved before recording?
• Is it held rigidly or must it remain movable within the device (e.g. rotating, swiveling, tilting)?

Positioning & accessibility

• What positions must the product occupy within the station?
• How many working positions are necessary?
• Which areas must be freely accessible?
• Is the work done manually, mechanically - or in combination?

Special consideration is given to situations in which:

• the worker works under the product,
• limited space is available,
• or forced postures must be avoided.

Weight, center of gravity & safety

• Product weights up to 1.5 tons are taken into account.
• Analysis of center of gravity position, eccentric loads, tilting and twisting torques.

The devices are designed in such a way that:

• the product is held securely at all times,
• tipping and falling risks are excluded by design,
• and loads can be removed in a controlled manner.

Stationary or mobile

• Is the station operated at a fixed location or is it moved within production?
• For mobile solutions: Requirements for trolleys, locks and stability during operation.

Process chain & interfaces

Devices are always considered in the context of the entire process chain:

• previous process step,
• subsequent process step,
• Transfers between man, machine and device.

This is analyzed:

• how many process steps are affected,
• how many product items are required,
• and whether unnecessary transformer or relocation processes can be avoided.

Avoidance of incorrect operation & errors (Poka Yoke)

• Can the product be inserted incorrectly, twisted or placed in the wrong position?
• If yes:
  • mechanical exclusion principles,
  • clear recordings,
  • form-fit coding (Poka Yoke).

Operating errors are prevented by design, not by organization.

Product contact & protection

• Which surfaces on the product may be contacted or loaded?
• Consideration of:
  • sensitive surfaces,
  • Functional and adhesive surfaces,
  • later assembly or test points.

The device protects the product and does not impair its function or quality.

Product variants & frequency of use

• Processing several products or variants at one station
• Evaluation of:
  • conversion effort,
  • Ergonomics,
  • Set-up and dismantling times,
  • Frequency of use (single unit, small series, continuous operation)

Conscious technical compromises are agreed transparently with the customer.

Implementation during ongoing operations

Many fixture projects are implemented during ongoing production operations. Production must not be impaired, or only minimally. We develop solutions that:

• optimize or expand existing stations step by step,
• can be introduced parallel to ongoing operations,
• and only fully adopted after successful validation.

Typical approaches:

• modular extensions,
• temporary parallel stations,
• successive conversion of individual process steps.

Adaptation of existing stations

A completely new development is not always necessary. Existing stations are often fundamentally suitable and need to be technically evaluated, specifically adapted or functionally expanded.

We analyze:

• existing weak points,
• Potential for improvement in ergonomics and safety,
• and implement optimizations where they bring the greatest benefit.

Prototypes & verification

Prototypes of the device are often realized before the start of series production, especially for new products or processes.

These serve this purpose:

• to verify assumptions from the design,
• test processes in real life,
• evaluate ergonomic and safety-related aspects,
• recognize risks at an early stage.

The prototype phase can:

• as a functional model,
• partially functional device,
• or near-series system.

Findings are incorporated into the series solution and reduce risks during the start-up phase.

Testing, verification & acceptance

Depending on the design and application, an assessment is made together with the customer:

• Classification as a load handling attachment
• Necessity of:
  • Calculation proofs
  • Overload tests
  • CE conformity

The type and scope of the inspection and the acceptance process are defined and documented on a project-specific basis.

Cleanroom - yes or no?

If a customer produces in or for the cleanroom, further specific questions arise. More on this under "Fixture construction in the cleanroom".