Greater flexibility and efficiency. This is the aim of Danish deep drawing specialist C&K Johansen in Horsens, Denmark as the company invests in the future with new automation solutions from AP&T.
Increasingly stiffer competition, not least from low-cost countries, is propelling development within the European sheet metal forming industry towards an increasingly higher degree of automation. Danish C&K Johansen produces a large number of different parts in small and medium-sized series for several different customers - often on short notice - which means flexibility is a crucially decisive factor of success.
"The faster we can reset from one product to another, the less the size of the batch matters," says C&K Johansen's director Peter Møller.
New flexible solution
In 2008, right in the middle of the recession, C&K Johansen decided to develop a solution with AP&T that would significantly improve the flexibility and efficiency of its production. The new equipment was in place and work was completed in January 2011.
Two existing hydraulic presses, which had up to that point been run manually, formed the point of departure - one at 500 tons and one at 1000 tons. Both of the presses are now fully automated and can be used separately or together. Both of them can perform one or more press operations depending on what type of part is to be produced, and they have been set for quick tool changes. The blank feeder can cope with sheet metal up to 1500x1500 mm with thickness up to 10 mm, a feature that only C&K Johansen can offer on the Danish market. What have really taken flexibility up a notch, however, are the four-axis SpeedFeeders that move blanks and parts to and from the presses.
Four-axis SpeedFeeders
"Using SpeedFeeders with four axes results in virtually unlimited flexibility. Not only can they move forwards, backwards, downwards and to the side, they can also spin around. Each SpeedFeeder has lifting capacity of up to 100 kg," says Peter Karlsson of AP&T.
All of the operations in the production process, from blank feeding and lubrication to finished pressed product, are quick and efficient, which is another important prerequisite for a high level of productivity.
"This solution provides a production speed that is three to five times faster than in the past. It also requires fewer workers since both of the presses can be run by one operator," says Peter Møller.
Meets future demands
This is not the first time C&K Johansen has invested in automation, nor will it be the last. All of the company's presses are already equipped with some sort of automation. For example, AP&T installed an automated press line with four presses, three SpeedFeeders, a shuttle and other equipment about a year ago. There is in all likelihood more to come.
"Anything can be automated if there is willingness to do so, and this is the path we are taking to meet future demands," says Peter Møller.
