It’s difficult to break bad handwriting habits once you’re older. What can we do about it? 

Handwriting doesn’t enjoy the same status as it once did. Back in the day, you would pull out your pen and notebook, but now smartphones, tablets and laptops are setting the agenda. This is undoubtedly practical, yet we quickly lose sight of the deeper significance of handwriting, which is more than just a quirky expression of our individuality. A study has shown that test subjects who jotted down notes by hand exhibited greater brain activity than those who resorted to using a keyboard, which suggests motor skills and memory are closely linked. In 2015, a survey conducted by the German Teachers’ Association and the Writing Motor Skills Institute among teaching staff revealed that only 20 percent of secondary school pupils in Germany have acceptable handwriting. The survey also claimed that a mere 38 percent were able to write comfortably for more than 30 minutes. So it’s pretty clear that learning how to write at primary school is of vital importance. A project from the Netherlands has now come up with innovative measures to tackle writing problems.

Getting the hand movements right from early on  

The “Sqriba” writing robot co-developed by students at Hague University of Applied Sciences and Delft University of Technology uses repetitive movement to improve handwriting. Philip Schara was one of the dedicated students who worked on this project and is taking it further with his fledgling business Jemax Robotics. “It’s actually a simple principle. When you repeat the same movement over and over again, it locks into your subconscious. This is also referred to as ‘muscle memory’,” explains Schara. As a result, developing messy or poor handwriting (known in slang terms as “chicken scratch”) at a young age means you will have a hard time putting things right later on. Sqriba intends to prevent this from happening in the first place and rectify specific grip problems.  

The schoolchildren are guided by a special pen with a small metal ball attached to the end. Rather than being controlled by the children, the pen is automatically steered by a small but powerful magnet under the table top, which is also an integral part of the Sqriba setup. A small touchscreen shows the pupils the letter they’re currently writing with the magnetic pen in its perfect form. This innovative combination of motor and visual feedback creates a new type of learning experience that helps young schoolchildren learn the correct way to form letters while they play around with this exciting technology. 

Having fun with writing 

The basic frame that holds all the individual elements together is made using profile technology from the item MB Building Kit System. Having worked with item profile technology on numerous projects as a mechanical engineering student, Schara was well acquainted with its versatility. And it certainly didn’t let him down for this writing robot, either: “The modularity of item really helped us right from when we first started working on Sqriba. We were able to try out new ideas and concepts without having to restrict ourselves in any way.” But there was another, rather pragmatic reason that spoke in favour of item. “It’s a happy coincidence of course that the item subsidiary in the Netherlands is just 200 meters from Hague University of Applied Sciences,” says Schara with a twinkle in his eye. 

Sqriba has already been successfully tested at three Dutch primary schools. One of these was the De Boeier school in Lelystad, where twenty fourth-year pupils were able to tackle their writing problems head on. Their difficulties are anything but unusual – letters are too big or too small, not using the correct grip, or simply not really being able to write at all. But by practising with Sqriba on a daily basis, the pupils were able to significantly improve their handwriting. Schoolteacher Ellen de Jong is delighted: “I am seeing clear progress, the children’s handwriting is steadier. And they simply have a lot more fun writing these days.” Further tests are planned for the near future in lower year groups, to help the pupils write faster, for instance. Sqriba will be released for sale in the Netherlands in September 2018. 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

More and more companies are catching on that employees need a break from sitting down. 

“Sitting is the new smoking!” As overly dramatic as this frequently quoted statement might seem, it nevertheless hits the nail right on the head. Although we spend most of our lives sitting down, we certainly aren’t built for such a sedentary lifestyle. In reality, sitting only became such a central aspect of daily life around 250 years ago. Spending too much time sat down puts your health at real risk, with effects ranging from muscular tension, higher blood pressure, headaches, arteriosclerosis and diabetes right through to increased risk of cancer. But a desk job isn’t dangerous in itself, of course. It all boils down to striking a balance and incorporating ergonomic principles into your day-to-day life. Even Apple’s CEO Tim Cook has long since recognised the advantages that height-adjustable work benches have to offer. 

Symbiosis of ergonomics and design 

Apple Park, the new corporate headquarters of cult brand Apple in Cupertino, is anything but run-of-the-mill. The huge ring-shaped campus reportedly cost 5 billion U.S. dollars to build and its unusual design has earned it the nickname “the spaceship”. Some 12,000 employees are based here in a building with a floor area of 260,000 m². CEO Tim Cook has been one of the most prominent voices to speak out against excessive sitting for quite some time now. For instance, he saw to it that the Apple Watch has a feature that notifies wearers when it’s time to get on their feet if they’ve been sat down for too long. But that was just for starters. 

Thanks to Cook’s initiative, all Apple employees at the new site now have a standing workbench. To put it more precisely, they have height-adjustable ergonomic desks, which means they can ease the strain on their backs (and other parts of the body) by regularly changing position. The desks can be moved up or down at the touch of a button, and are kitted out with fibre-optic and electric cables. One thing is certain – Apple has really splurged to keep its employees in tip-top condition. The office chairs alone each came with a price tag of around 1,180 U.S. dollars. Given the size of Apple’s workforce, that brings the total bill to approximately 14 million U.S. dollars. It goes without saying that the tech giant’s ergonomic strategy has been married perfectly with its renowned flair for elegant design. 

Ergonomic work benches for industry 

Apple’s ergonomic office desks for its Silicon Valley staff are undeniably exemplary, but physical strain whilst seated presents an even greater problem for production workers. Particularly when it comes to manual assembly work, employees are known to develop a lop-sided posture that often leads to uncomfortable back problems. In an industrial context, (electrically) height-adjustable work benches are therefore recommended – particularly in shift operations with frequent staff changeovers. These enable employees to alter the height of their bench to suit their personal requirements. On top of that, the flexibility of such ergonomic work benches – including like those at Apple – allows users to eliminate specific types of strain. If employees have been sat down for a long period of time, they ought to switch to working standing up. 80 % dynamic sitting and 20 % standing has proven itself to be an effective ratio.

Ergonomics is important as an overall system – which is why the work benches from item have been awarded the seal of quality from the Campaign for Healthy Backs (AGR e.V.).

A state-of-the-art work chair must be fully adjustable so it can be steplessly adapted and therefore support back-friendly working practices. Employees should be able to carry out adjustments whilst still sitting down, as only then can they determine whether the chosen setting is really the right one for them. Robust and easy-to-clean upholstery, synchronised mechanical systems and adjustable lumbar support are yet more quality criteria for work chairs in industrial settings. Yet ergonomics is about much more than just sitting – it covers lighting, modularity, handling areas and design, for example. From day one, design and therefore the fusion of form and function have been at the very top of the agenda at item. When you look at what the big players from abroad are doing, it becomes clear that Germany’s SMEs mustn’t sell themselves short.

Are you interested in ergonomics and what the working world of the future will look like? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

As an industrial designer at NASA, Molly Harwood faces Herculean challenges. 

Women are fortunately no longer a rare sight in technical fields. All the same, there are still plenty of gender stereotypes surrounding career choices – for example, whilst women reportedly like to use their imagination, men are said to be more practical. However, many jobs in industry combine these supposedly separate worlds. To be successful, you need to question the status quo and discover creative new solutions – which also means being inquisitive, giving things a go, and having fun tinkering about. American industrial designer Molly Harwood from NASA enjoys doing exactly that and has made it right to the top in her career. After engineering manager KJ Cocke and industrial engineer Fabiola Calderón, Harwood is the third inspiring female personality to feature in our series of posts dedicated to this topic. 

Gaining a practical insight is key 

Harwood wasn’t always dead set on pursuing a technical occupation. Originally, her passion was drawing. “I studied at the Rhode Island School of Design and there I originally went for illustration,” says Harwood. “But I became interested in industrial design after I started to make things. I think my school places a really large emphasis on making and learning from hands-on experience.” This correlates with numerous studies, which illustrate that women in particular use their creativity and communication skills to solve engineering problems. It is vital that female students get an opportunity to gain an insight into the practical world of work, as this is often the very first step leading up to a career in one of the STEM subjects. 

For Harwood, that initial taster was a light-bulb moment. After encountering industrial design for the first time, she was constantly on the lookout for new challenges. “I wanted to design things that were even more ‘extreme’ or efficient than what had gone before,” she says. Harwood was particularly drawn to the idea of enhancing the efficiency of products designed for harsh conditions. As a result, it seemed only natural for her to turn her attention to outer space, where extremely robust objects are less of an option and more of an absolute must if you want to survive. “I decided to take the position at NASA because it represented a huge challenge. Designing for such extreme environments is one of the hardest things to do in design,” she points out. “You never have all the details you actually need for the design and you don’t know what the astronauts will have to face under these kinds of conditions.” 

Inspiring women to take up technical professions 

Such immense challenges were the perfect opportunity for Harwood to continuously expand her knowledge and fine-tune her skills as an industrial designer. Once again, Harwood’s experience matches reality. Attractive opportunities to develop abilities and climb the career ladder are key factors to retaining clever female minds in technical fields. Some of them may well balk at the idea of constantly having to come up with creative solutions for problems involving so many unknown variables but, in Harwood’s case, that’s exactly what spurs her on: “New challenges emerge every day, and that’s what motivates me the most.”

At the heart of it, designing for space is “very complicated and a very long process,” says Harwood. At the same time, her work is richly rewarded, particularly when she makes progress developing objects that help astronauts to capture data in outer space. After all, by doing so, she is playing a big part in helping us gain a better understanding of the universe. “Every day we get a little bit closer so that’s exciting. I’m really proud to be a part of it,” says Harwood.  

Want to be bang up to date on the latest news from the world of technology? Simply subscribe to the item blog by completing the box at the top right!

How a modular solution revolutionizes the process of making cocktails. 

Cocktails are just bursting with fruity flavour. For many of us, these ice-cold beverages are part and parcel of any successful (summer) party, especially seeing as you don’t need alcohol to conjure up culinary masterpieces. All the same, making cocktails on a larger scale causes quite a few problems for event organisers and restaurateurs, with demand spiralling almost out of control during busy periods and intervals. Thousands of cocktails need to be mixed in an incredibly short space of time. Although preparing them in advance is an option, it’s hardly the best way of doing things. After all, you can’t plan exactly how many people will come to the bar. ‘Inventory shrinkage’ is another issue. Bottles fall onto the floor or a barkeeper is a bit too generous with a certain ingredient, and planning starts to fall apart. It’s all about getting the balance right. That’s why Timm Kasischke came up with a practical solution to such challenges that is patented throughout Europe. Raise a glass to the cocktail-box. 

A conveyor belt of cocktails 

Whilst he was still studying medical technology, Kasischke was keen to explore whether the idea of a cocktail machine was technically feasible. “There’s always lots of things that can go wrong when you make a cocktail. I came up with the idea of developing a machine that can make cocktails in large volumes at the touch of a button.” In 2006, the first prototype, developed in his parents’ garage, came into action at a student party. Although the cocktail machine has changed significantly since then, the underlying idea has remained the same. Thanks to the clever composition of the individual ingredients, cocktails of consistent quality are made at the simple touch of a button. Further experience at events and during his employment at a medical device company allowed Kasischke to constantly improve the cocktail-box and expand his company, which he founded in 2009.  

This method of automatic cocktail production is based on a combination of a recipe database and a pump system. “In principle, every ingredient is allocated its own pump. The machine then dictates which pump is needed and for how long,” Kasischke explains. The individual ingredients, meanwhile, are stored in separate 5- or 10-litre containers inside the cocktail-box and only come together in the cocktail glass – ruling out the possibility of any cross-contamination that would impact on the taste. Depending on the cocktail’s recipe, the entire mixing process takes between four and eight seconds, meaning 300 to 500 cocktails can be made every hour. Users can conveniently control the cocktail machine via touch screen – there’s no need for any specialist knowledge. “At the heart of it, it’s as easy as pulling a pint,” says Kasischke. 

A cocktail machine for all your needs 

We’ve all got different tastes, and cocktails are no exception. That’s why the cocktail-box allows you to add as many recipes to the database as you wish. This flexibility is also the defining feature of the cocktail machine’s overall concept. The solution is based on modular one-metre-wide bar counters that are joined together, meaning you can attach as many extra counters as you like. Kasischke’s team opted for the profile technology of our MB Building Kit System to construct the frame: “We used to do business with a competitor, but they weren’t as good in many respects. item simply provides us with greater flexibility. We have customers that need something extraordinary or want to expand an existing bar counter. This is where item products are naturally fantastic, because of their modular design.” Customised lighting and a fully branded look can also be created.

But that’s not all the machine has to offer. Besides a mobile variant that has proved a big hit at trade fairs and other large-scale events, there is also a stationary cocktail machine. This variant is placed on top of an existing bar counter and thus doesn’t require any extra space, making it the perfect choice for restaurants or bars. There’s no need for design modifications, drilled holes or openings, either. “Some of our customers are restaurateurs who have already put our cocktail machine to fantastic use in order to take some strain off their employees,” says Kasischke. The mobile variant, meanwhile, has ventured even further – in the form of a cocktail machine integrated into an electric vehicle owned by the company StreetScooter. Who knows what other exciting ideas are next! 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

Algae farming is a new and highly promising branch of the life sciences sector.

Algae farming has become increasingly important in the pharmaceutical and nutraceutical industries over the past few years. Numerous types of algae possess properties that can boost our immune system, which opens up a new pool of active ingredients that have yet to be put to use. Manufacturing such ingredients, however, places high demands on factory equipment – as item discovered when it designed a modular enclosure solution for six photobioreactors at Wrocław-based Algae Labs Sp. z o.o. Microalgae are grown inside these bioreactors to derive astaxanthin – a reddish and naturally occurring substance that is produced by Haematococcus pluvialis and is classified as a carotenoid. Astaxanthin possesses antioxidant properties and offers high UV protection that cannot be washed off – which explains why it is proving very popular among athletes in particular. 

Algae farming has special requirements 

Up-and-coming Polish company Algae Labs currently employs eleven workers and focuses on researching and developing the microalga Haematococcus pluvialis as well as producing and commercializing astaxanthin. Planning the new modular enclosure for a station with photobioreactors for manufacturing biomass involved meeting special requirements. Besides factoring in the dimensions of the six installed plants – 250 cm x 5 cm x 5 cm – the enclosure design also had to accommodate their 250 kg weight. Being able to ergonomically remove the heavy cultivating containers was a must, too. Another key factor was ensuring the factory equipment remained sterile, as the microalga is susceptible to contamination from other algae, fungi and bacteria. This meant the equipment had to be assembled under cleanroom conditions. 

To ensure the containers could be cleaned thoroughly and regularly, the modular enclosure also had to be engineered so that the photobioreactors could be easily taken out and replaced at any time. In keeping with these requirements, planning focused on a design that used the aluminium profiles from the item Line X. Thanks to the multi-chambered frame, lab technicians can control individual algae farming processes separately. The unbroken surfaces and the minimised edge radius that ensures a seamless transition between individual profiles make Line X perfect for applications that demand high hygiene standards. Once the algae has been cultivated, the design ensures the bioreactors can be safely and ergonomically removed. 

Perfectly suited to life sciences 

After item staff had prepared the modular enclosure, Algae Labs saw to the assembly themselves. The team members from the Polish laboratory were extremely satisfied with our profile technology’s properties and immediately won over by the modular structure, intercompatibility and high-quality design. This fruitful collaboration to plan and install the modular enclosure has led to even more applications being jointly implemented. Michał Grzebyk, Deputy Director of Algae Labs, strongly believes that the solutions from item are well-suited to the life sciences sector because they support customised engineering that factors in laboratory requirements. Assembly is done under cleanroom conditions and there is always the option of making last-minute changes to projects that have already been designed. 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

From university graduate to entrepreneur – favourable framework conditions on campus are invaluable for innovations.

Plenty of bright minds, intensive intellectual exchange and the drive to make a difference – universities offer the ideal environment for establishing a start-up, as we have previously described in our blog post on test systems. A scientific spin-off is a particularly effective vehicle for getting new technologies into use in industry, with university research work forming the foundation on which the start-ups are built. This is also how the rising stars behind Aachen-based Meotec came to establish their business. The company specialises in the electrochemical surface modification of magnesium for absorbable implants. In this post, we will highlight the benefits of the process and show how the company puts our profile technology to good use. 

Absorbable implants with an added bonus 

After completing his mechanical engineering studies at RWTH Aachen University, where he majored in production engineering, Alexander Kopp founded Meotec in 2011. His start-up was the first company to receive support from the Cluster Biomedical Engineering headed by Professor Thomas Schmitz-Rode. This support included use of the new buildings on the Melaten campus. The company is now based at Triwo Technopark Aachen. Building on Alexander Kopp’s dissertation research, Meotec developed absorbable magnesium implants for fixing fractures, including bone screws and plates, for example. 

Absorbable implants – that is to say, implants that dissolve in the body, thereby eliminating the need for a second operation – have been around for a while. “However, since our implants are made of magnesium rather than polymers, they are stronger and less prone to deformation,” says Kopp. One key step is needed to make the magnesium suitable for the planned area of application since, without it, the implant would be absorbed too quickly by the body, which could ultimately lead to rejection. Thanks to a special surface treatment, the absorbable magnesium implants dissolve gradually over a carefully planned time frame. As a result, the healing bone always has the space it needs. According to Kopp, the combination of high-quality materials and controlled absorption is a “revolution that will transform the market”. 

Customised solutions for special requirements

To meet the needs of a major medical technology customer that produces implants and other medical devices, the company had to develop a highly specialised surface treatment plant for the magnesium. This involved much more than just a technological enhancement. “Part of our profile is that we deliver more than just theoretical technology, we also ‘industrialise’ it,” says Kopp. Inside the plant, which is built using our Line XMS, the implants are first washed then covered in a ceramic conversion coat. Here too, the components are made of magnesium that is converted into a magnesium ceramic. A validated final cleaning process follows in the same plant so that the parts can be packaged.

Since the products and plants from Meotec tend to be highly specialised, they are generally one-offs, and so require an extremely diverse range of materials. The building kit system principle, which has been at the heart of item since day one, is the ideal solution. In addition, there are the quality requirements for clean rooms that are typical of this industry. The characteristics of XMS in this regard were “one of the determining factors” in the decision, says Kopp. Thanks to its series-standard sealing groove and smooth, unbroken outer surfaces, the strengths of Line XMS really came to the fore. 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

It is now easier than ever before to uncover mechanical doping in cycling.

Doping is an ongoing issue in cycling, and is damaging the image of the sport. The International Cycling Union (Union Cycliste Internationale, UCI) is therefore at the forefront when it comes to developing countermeasures. Doping refers to both medical manipulation using erythropoietin (EPO) or similar substances and deliberate technical violations. Initially, the latter generally involved using a racing bicycle that weighed less than the minimum weight. The lighter bicycle was secretly replaced during the race, so that the rider would arrive at the finishing line on a legal one. The rapid evolution of e-bike technology has now given rise to another, more effective form of doping, however – motor doping. With the help of a miniature motor, dishonest cyclists can save themselves a lot of hard work. The UCI uses a mobile X-ray machine to keep an eye out for this kind of cheating. The technology has been developed as part of a transatlantic collaboration between HEITEC PTS (Germany) and VJ Technologies (USA). The German company (previously Erhardt + Abt), based in Kuchen in the Baden-Württemberg region, was founded over 20 years ago, and specialises in industrial X-ray technology. 

Electric power for an illegal extra drive boost

Professional cyclists looking for a short-cut don’t use a conventional e-bike motor, which can deliver about 250 Watts. They only need the help of an extra 20 or 40 Watts to gain a minimal but decisive edge. The highly trained legs of professional cyclists can produce 400 Watts of drive on their own, so it is no wonder that such a small boost can make a difference. “It only takes a small motor that runs on mini batteries. These motors are generally hidden in the seat tube – that is to say, the part of the frame that extends from the saddle to the bottom bracket,” says Christian Abt, Managing Partner of HEITEC PTS. Activated by a little button, such a motor can allow cyclists to save energy during a climb, for example, enabling them to score points in the final section.

To make matters worse, there has previously been no easy way of proving this kind of cheating. With the number of lightweight materials available for constructing racing bikes, it is easy to compensate for the additional weight of a motor by using lighter components elsewhere. As a result, there is no discernible difference between the modified bicycle and a legal model when it is placed on the inspection scales. Metal detectors can’t pick up every trace of mechanical doping either, as the electric motor is positioned right next to the gears and pedals, where there is already a lot of metal. The same applies to thermal cameras, as it takes just ten minutes for the motors to cool completely. 

Motor doping inspections are becoming more rigorous

In spring 2018, the UCI therefore unveiled its new tool in the fight against motor doping – a mobile X-ray machine. Weighing a total of two metric tons, the X-ray inspection equipment on wheels will soon be rolled out at the Giro d‘Italia, the Tour de France and other international cycle races, where it will conduct X-ray scans of riders’ bicycles at the start and the finishing line. The responsible mechanic pushes the bicycle into the X-ray cabin. This is where the profile technology of our MB Building Kit System comes in, forming the fixture that positions and fixes the cycle in place. 

“For a start, we have been familiar with item for 20 years. On the one hand, we chose item because it just makes us so flexible. On the other, we are using a driven linear axis that enables us to achieve pre-set positions automatically. This kind of system solution from item, with everything coming from a single supplier, is hugely advantageous,” says Abt. Once the bicycle is inside the cabin, all the most important points are closely examined by the UCI inspector. These include the frame at each of the wheels and in the area around the bottom bracket. After the inspection, a seal is applied to the bicycle to clearly identify it. 

A flexible approach to combating motor doping 

Although there is now a proven method for combating motor doping, it doesn’t completely eliminate the potential for dishonest cyclists. While the bicycles – including the replacements – are strictly examined based on various strategies, there is no way of constantly monitoring what happens with riders at the rear of the field in their service vehicles and whether a replacement bicycle is manipulated after the inspection and then sent into the race. All the same, the mobile X-ray chamber from HEITEC PTS represents the best tool currently available to detect motor doping. The deterrent effect shouldn’t be underestimated, either. And what does the future hold? “Thanks to the aluminium profiles from item, we are extremely flexible. If we have to make modifications or handle a different kind of bicycle, the geometry might change, but that’s not a problem for us,” says Abt. 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

The world’s largest 360° display in the world’s largest car delivery centre – and item is at the heart of it all.

Germany has always been a nation of fervent car lovers. This fascination for vehicles is clearly illustrated by the Autostadt, which opened in Wolfsburg back in 2000 and cost around 430 million euros to build. In addition to the car delivery centre, the Autostadt also houses numerous facilities for exhibitions, concerts, shows and culinary experiences spread across more than 28 hectares. The pièce de résistance, however, is the car delivery centre itself, known as the “CustomerCenter”, where customers can pick up their new Volkswagen or SEAT in style. Our aluminium profiles also make an appearance in this remarkable atmosphere, forming the supporting frame of a 360-degree display in the waiting area – yet another world record breaker in terms of size. Using magnetically controlled discs called ‘flip dots’, the display shows the proud owners of brand-new vehicles when they are next in line to collect their new wheels.

Making a great impression on new vehicle owners

There’s a short sound and the countless flip dots on the ring-shaped display whirr into action above the heads of the waiting customers, coming together to spell out the pick-up times and names. This was the vision that was suggested in response to VW’s invitation to tender for a display – and it ultimately won the contract. Concept planning and project management were taken care of by Uwe Urbas from Polyphon. Christopher Bauder from WHITEvoid, who saw to the project’s art direction and design, tasked the team from mawa led by Martin Wallroth and Steven Morgan with planning, manufacturing and installing the display. On board the team of developers hired for this prestigious project was Konstantin Weickardt, who worked on the test structure in Babelsberg and the final installation in the Autostadt in Wolfsburg. 

mawa has made a name for itself by focusing on developing its own custom lights and technical lighting solutions. From time to time, however, the mawa team deliberately takes on a project that forces it out of its comfort zone and helps it add new skills to its portfolio. In this case, the aim was to put its engineering capabilities to the test. The team turned to our Line 6 profiles in the dimensions of 30x30 and 60x30 for the supporting frame of the 360-degree display. First, however, the profiles had to be bent on the in-house CNC bending machine, factoring in the various radii. Although item doesn’t bend any profiles itself, this exceptional example shows the potential for such projects. As Weickardt reports, item had earned mawa’s trust based on previous positive experience with our profile technology: “Our head planner had already used item products to great effect – he’s the one who pointed us in the company’s direction. That’s always the best kind of recommendation.”

Modular ring construction – specially created for the Autostadt Wolfsburg

However, the head planner in question had never worked with item on a project of this size – and this was one big job. 180,000 flip dots cover the ring construction, which boasts a diameter of nearly nine metres and is suspended 3.6 metres in the air. Its dead weight of 2.4 metric tons is pretty impressive, too. These conditions really brought out the best in the modular design of the MB Building Kit System, which helped ensure this pioneering project was a success. 

For instance, the entire installation can be dismantled into 44 individual ring segments and easily transported in flight cases. “You could disassemble the construction, pack it up and reassemble it at the drop of a hat,” explains Weickardt. But let’s turn our attention back to the flip dots. How exactly do they work? “The technology isn’t exactly simple,” the engineer tells us with a twinkle in his eye. Flip dots are thin discs, each side a different colour, that are controlled with pinpoint accuracy using magnets. Thanks to this technology, the project team can program writing that moves around the entire ring or even different motifs, offering Autostadt visitors a real 360-degree feast for the eyes. 

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

The 7 Muda are widely known, but they aren’t the only types of waste in production. 

The Toyota Production System (TPS) that emerged in the 1950s is thought to be the nucleus of lean production. To this very day, Toyota has had its sights firmly set on reducing lead times. A quote from Taiichi Ohno, the founding father of the TPS and thus to a certain extent lean production, clearly illustrates this: “All we are doing is looking at the time line, from the moment the customer gives us an order to the point when we collect the cash. And we are reducing the time line by reducing the non-value adding wastes.” 

In lean terminology, these non-value adding types of waste that increase lead time are known as Mura (“imbalance”), Muri (“overloading”) and Muda (“waste”). As they all start with “M” and are all closely connected, they have been dubbed the “3M”. By the way, they are also identical to the three factors in the Kingman Formula that negatively influence lead time. Although companies often concentrate on Muda, the most important of the three Ms is actually Mura. 

Mura and Muri skew the balance in production

How should we interpret “imbalance” in the context of lean production? As usual, it helps to take a look at what actually happens on the shop floor and focus on the Gemba – the place where value is actually added. A typical example of Mura is when a company overloads one resource (i.e. a case of Muri) whilst barely utilising another, if it at all. Even where there is just one resource, it is not uncommon to find this kind of interplay between overloading and insufficient utilisation. When Mura occurs, it generates two types of losses. On the one hand, queues start to build up upstream of the overloaded station and these significantly hamper productivity. On the other, failing to use capacity to its full potential also contributes to a loss of added value. All in all, this reveals weaknesses in coordinating the individual processes.     

Such a lack of harmony in process coordination is a typical cause of overloading, also known as Muri. This can have a considerable impact on employees, with excessive psychological pressure and harsh physical strain quickly taking their toll – particularly if ergonomic principles have been ignored. But it’s not just staff that are affected – working materials also take a hit. Besides short-sighted planning, unclear work instructions and communication problems can create a breeding ground for Muri. The just-in-time principle has become a tried-and-tested measure for counteracting overproduction. The underlying idea is that material is only delivered and processed if there is an actual need to do so, which first and foremost prevents the build-up of high stock levels. 

7 Muda – actively combating waste 

The 7 Muda are one of the best-known and clearest lean concepts, but by no means should they be underestimated (we’ll explain further in just a second). Muda translates as “useless activity” or “waste”, which is why you often hear people talk of “the seven wastes”. We have already outlined the concept of Muda in a previous two-part special blog (see the first and second parts here). Given the complex interaction of different stakeholders and elements, it’s not surprising that there are countless points in industrial production where waste occurs. But, as we have already seen with Muri, “waste” has a much broader definition in this context than it does in everyday life. So here are the 7 Muda alongside some tried-and-tested countermeasures: 

1.) Superfluous movement of materials

Due to the labour and energy use involved, transporting materials leads to higher costs. At no point is added value created here. Don’t forget that materials can be damaged when being transported, too. It is also advisable to carefully reassess routes that seem to be tried and tested. 

Practical tips: Position work stations closer to one another, time and interlink work steps (if possible). 

2.) High stock levels in warehouse  

An over-stocked warehouse is never a good sign. It shows there is definitely something going amiss at the planning stage. The probable root of the problem is that it isn’t clear what materials are needed in which quantities. Of course, not having enough materials is just as undesirable. 

Practical tip: Stabilise and, above all, standardise processes. 

3.) Non-ergonomic movements

Actions such as bending over or spending too long looking for something are problematic for two reasons. Firstly, they don’t generate any added value. Secondly, they often lead to employees developing poor posture, which can cause painful and long-term harm. 

Practical tips: Respect the basic principles of industry ergonomics, use a modular ergonomic work bench system.

4.) Avoidable waiting times 

Admittedly, waiting times can never be fully eliminated. Yet there are certainly issues that can be addressed, such as misplaced work materials, delivery bottlenecks and carelessness that has knock-on consequences. 

Practical tips: Deploy staff to their full capacity (e.g. by ensuring they can cover various different stations), increase their skills by extending their scope of duties. 

5.) Processing 

Unnecessarily complicated work stages create waste, too. Overly elaborate designs might be pretty to look at, but it’s the functionality alone that counts. You should always aim to achieve a perfect symbiosis of form and function. 

Practical tips: Be minimalist – CIP is more important than time-consuming excessive perfectionism. 

6.) Overproduction 

This is where Muri comes into play. You’ve misjudged demand, capital is tied up for too long, and the quality of goods and materials could well deteriorate while they are in storage. 

Practical tips: Establish a needs-based production method, align your process chain with the customer’s time line. 

7.) Meta level – continuous improvement 

CIP should always be at the forefront of your mind whenever you take measures against the different types of waste, as only then will the Muda methodology reach its full potential. If you keep a close watch on things, you can continue to improve production day by day.

Mura – the source of waste 

The 7 Muda are highly popular and pretty comprehensive, but don’t get your terms mixed up – Muda isn’t the source of waste, Mura is. In spite of this, there are still plenty of companies that don’t really take the practical implementation of the lean philosophy very seriously. Most of the time, they focus on tackling Muda. Occasionally, they go as far as thinking the Muda methodology is exactly the same as lean production. Given that the 7 Muda are easy to grasp – particularly when compared to other lean concepts – this reaction is completely understandable. Ultimately, in practical terms, it is easy to track down the various types of waste. 

Yet taking a rather superficial stance to this issue usually leads to productivity losses. For example: Company X notices that stock levels are high. The business recognises the problem solely as Muda no. 2 and reduces its stock. However, there’s always a specific reason why stock levels are high in a particular system. Reducing stock in this way does not therefore get at the actual root of the problem – the company has lost sight of Mura. Most importantly, reducing stock levels in an unstable process stops operations running smoothly, as maintaining a large amount of stock has a specific function – it serves as a cushion.  

Tackling Mura with Heijunka 

You should always be aware that unstable and uneven processes – in other words, those characterised by Mura – lead to Muda. In fact, Mura often brings about both Muda and Muri – hence its less-than-complimentary and unofficial title of “source of waste”. But just how does the great role model Toyota deal with this troublesome creature? This is where Heijunka (levelling and smoothing) plays a vital role. The lean method goes beyond the conventional levelling of production, which splits products manufactured within a certain time frame into day rates. Heijunka divides these day rates into further sub-quantities. Ideally, a batch size of 1 is produced so that all processes are perfectly incorporated. Material is always available in sufficient quantities and production staff no longer have to worry about fluctuating stock levels.  

Are you interested in fascinating reports and innovations from the world of lean production? Then we have the perfect solution for you – Simply subscribe to the item blog by completing the box at the top right!

Functionality and cutting-edge design – a combination that item has mastered, winning it the Red Dot Award 2018.

The more than 6,300 products competing for one of the coveted Red Dot Awards in 2018 came from a total of 59 countries, and each and every one was scrutinised by an international and independent panel of judges. As in previous years, the key criteria for winning one of the world’s most highly regarded competitions for outstanding product design included achieving the best possible combination of clear product language and innovation – and the Toolpanelsystem from item scored top marks. Thanks to its clear structure and numerous options for attaching tools, the Toolpanelsystem impressed the judges as an efficient solution for organising work benches. That saw the award added to the string of design prizes item has won. 

Perfectly organised thanks to the item Toolpanelsystem

With a total of 19 system grooves on the front and rear, the aluminium Groove Plate Profile crams plenty of space for holders and accessories into the most compact dimensions. The panel-like design of Groove Plate Profile 8 helps staff organise their workstation with the greatest of ease in next to no time. Accessories and working materials can be positioned separately at the ideal height and in the perfect arrangement. Whether spanners, screwdrivers or bits, virtually any tool can be adapted to the relevant working scenario. What’s more, users simply twist corresponding holders directly into a groove, without needing any tools to do so. A work bench that has been well prepared with the item Toolpanelsystem helps deliver more efficient working processes that boost productivity.

The item Toolpanelsystem is also the ideal complement to the MB Building Kit System for ergonomic work bench design. Groove Plate Profile 8 can be combined with all other products in the Hook and Holder System, Shelves and other custom fixtures from item. Besides connecting it directly to a work bench, users can also integrate the item Toolpanelsystem into a well-organised and mobile tool carrier and thus bring more organisation and structure to many different areas of production. 

Honouring the best that the industry has to offer – the Red Dot Award

The prestigious Red Dot Award is presented by the “Design Zentrum Nordrhein-Westfalen” association (Design Centre North Rhine-Westphalia, or DZNRW), which looks back on a 60-year history. Established in Essen in the mid-1950s, the association operated under the name “Verein Industrieform” (Industrial Design Association) until 1990. Shortly after it was formed, it launched an annual national design competition that was initially dubbed the “Roter Punkt” and went on to become the international “Red Dot Award” around the start of the new Millennium. 

In addition to product design, the prestigious Red Dot Award is also presented for outstanding achievements in the categories of Communication Design and Design Concept. Besides carrying out the typical tasks of a judging panel, members who are entitled to vote must also have exhibitions and publications to their name. The Red Dot Award 2018 won by the item Toolpanelsystem singles out its ease of use and consistent design language. No matter what products or solutions the designers and product engineers at item are working on, their aim is always to achieve the perfect synthesis of functionality and design. Of course, it’s all the more rewarding when that hard work is officially recognised – as it has been with the Red Dot Award 2018.

Want to keep up to date with all the exciting innovations from the world of item? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

How a tried-and-tested conference format has been brought bang up to date. 

Conferences and congresses are as frequent as they are popular across the whole higher education sector. And the principle of “see and be seen” is just as valid at these events as it is anywhere else, with delegates giving presentations, sharing ideas and making highly promising contacts with other researchers. There is, however, another element to these events that is perhaps less well known outside he world of STEM, but is exceptionally effective all the same – the poster session. During a poster session, (up-and-coming) scientists stand in front of a poster displaying their research results. The posters are primarily a vehicle for the graphical presentation of data and ideally help to spark interesting discussions with passers-by. There’s even a special blog dedicated to poster sessions. However, a scientific researcher working on Fluid Process Engineering at RWTH Aachen University felt it was time the posters got a digital upgrade. 

Using digital technology to showcase results 

The growing popularity of poster sessions over recent years had not gone unnoticed by Armin Eggert. In fact, in 2017, around 1,800 posters were printed out at his university for precisely this purpose. However, he was also struck by one fundamental discrepancy: “I always wondered why the whole process hadn’t simply been digitalised. After all, we run a lot of simulations for processes and technical plants and we make video recordings of experiments, too. You can’t present any of that on paper, so there’s a lot missing, unfortunately.” Eggert also felt the flexibility that comes with digital technology presented another advantage – unlike printed posters, content can be fairly easily modified shortly before it is presented.

Although the odd digital poster has indeed put in an appearance at sessions in the past, the displays have always been too small and the resolution too low. Ultimately, visitors are around a half to a whole metre away from the display as it is presented and have to process some pretty complex specialist information. For this reason, the analogue posters are usually printed in a format that can be easily read from a certain distance, specifically A0 size (84.1 cm x 118.9 cm).

“Given the rapid pace of technical progress, 4K resolution, i.e. 3840 × 2160 pixels, comes pretty close to the quality offered by paper posters. Screens have become much larger, too, with a 65-inch display providing 20 percent more space than an A0 paper poster,” points out Eggert. It was clear that a display like this simply had to be developed. The next issue to consider was mobility – what would be the best way to transport the material needed for a digital poster session? A solution that had to be repeatedly disassembled and reassembled wasn’t an option. Trip hazards caused by a lack of power outlets and the associated extension cords and cables also posed a problem. 

Tried-and-tested material, digital planning

Finally, the engineer hit on a stellar idea: “Why not create a solution based on a battery system that is integrated into a poster trolley and then put the whole thing on wheels?” When it came to designing the necessary framework, item was at the top of the list due to past experience. “We like working with item materials here at the university, so it didn’t take long at all to decide to use them in this project, too.” The design is based on our Line 8 profiles. In the past, projects like this meant getting the Institute’s mechanical workshop involved to put together drawings, take measurements and machine materials. 

This time, however, the project team decided to use the online item Machining Tool for the first time, which made things much simpler. The ability to access and edit previously saved projects and the fact there was no need for additional software proved particularly popular. Equipped with Castors, the finished poster trolley can be easily moved to wherever it is needed, while battery life of up to 36 hours means the system doesn’t need to be set up close to a power socket. Data for the presentation can be transferred from a connected laptop or USB stick and can be saved locally onto the device. The system is also compatible with all standard Office programs, with PowerPoint playing a particularly important role when it comes to presentations. 

Practical leasing for digital poster sessions 

There has also been a sound business idea behind the concept for quite some time – leasing out the digital trolley for poster sessions. A truck full of displays could be driven from conference to conference, with five poster trolleys each carrying two displays – i.e. ten digital posters in total – fitting on one europallet. Customers could reserve a display and upload their data very easily via an online platform and could even quickly and conveniently make changes to their text and graphics shortly before the start of an event. The whole on-site setup process couldn’t be easier either, with no need to lay cables. Eggert is currently trying to find partners to work with and we’re excited to see what happens with this innovative project.

Do you want to keep up to date on the various ways our solutions can be put to use in university environments? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

A comparison of two (seemingly) totally different lean principles.

We’re very experienced when it comes to the methods of lean production and have touched on them here many times before. However, in a world as rich and varied as that of lean production, it’s hardly surprising there are still some “undiscovered gems” on the “lean map” that are well worth a mention on the item blog. And that’s precisely what’s coming your way in this post, as we take a look at the lean concept of Kaikaku, which is frequently described as the opposite of Kaizen. Often mentioned in the context of lean management, the term Kaizen combines the Japanese words for “change” (Kai) and “for the better” (Zen). Basically, Kaizen describes the attitude of pursuing improvement. The key in Kaizen, however, is that this process of improvement never ends – and that possibly gives away how Kaikaku is different. 

From Kaizen to the continuous improvement process (CIP) 

Although the term Kaizen is used frequently with regard to the lean concept, it is necessary to draw a distinction. In Japanese culture, Kaizen has worked its way into numerous areas of life and discourse. When Kaizen is applied specifically in production, we talk about the continuous improvement process (CIP). It is important to stress that this is a measure implemented by the entire workforce. After all, it is the individual employees who work day in, day out at the Gemba, i.e. the “actual place” where value is created. 

Although management are well advised to see the continuous improvement process in action with their own eyes during regular Gemba walks, the Kaizen philosophy cannot be enforced on a top-down basis. Instead, it has to be put into practice on a daily basis. This produces a positive fault culture that encourages everyone to examine what they are doing and get better all the time. The right tools and defined rules are crucial components for success.  

Kaikaku vs. Kaizen/CIP?  

As sensible as it is to pursue gradual improvements based on Kaizen or CIP, that isn’t always the perfect means of achieving the desired change in every single set of circumstances. However, the lean philosophy is rich and varied enough to offer alternatives. One of these is Kaikaku, a Japanese word that can be roughly translated as “radical change” or “reform”. That in itself highlights a contrast to Kaizen. Kaikaku is not about continuity or a never-ending process, it is about a precisely timed campaign that brings a new direction. For this reason, it is also sometimes referred to as “breakthrough Kaizen”. 

A typical example of Kaikaku in action would be an innovation project such as restructuring a production system. And, although this kind of project is implemented from the top down, that does not mean Kaikaku and Kaizen/CIP are “rivals” – quite the opposite, in fact. Kaikaku is often used to create a basis on which Kaizen, in the form of CIP, can be rolled out. One example would be the introduction of a U-line based on our Profile Tube System D30. Without a far-reaching change to the assembly process, it would not be possible to transform working methods. As a result, in this case, new methods are first rolled out as part of an organised process within a specific timeframe so that staff are then empowered to put into practice the philosophy of continuous improvement independently. 

How to efficiently harness and correctly communicate the advantages of digitalisation.

In light of growing customer demands, throughput times in today’s mechanical engineering sector are becoming ever shorter, which piles the pressure onto companies and their employees. That’s why it’s crucial that companies are quick to grab new opportunities to optimise processes for the future of mechanical engineering design. In the following interview, expert Florian Palatini, head of sales at item, explains how digital engineering intelligently expands and seamlessly combines long-established digital elements of mechanical engineering. He shows how it is often relatively small interventions that – when put to good use – give companies a distinct edge on the competition.

What is digital engineering and how does it affect me as a mechanical engineer?

After years of grappling with the theory and concepts behind Industry 4.0, companies are now incorporating more and more aspects into their actual business operations and their employees’ day-to-day work. It’s not about digitalising an entire factory in one go, but rather transitioning to the digital era one area at a time. Prime examples include supervisors monitoring machine data via an iPad, machines automatically ordering goods and the increased use of intelligent automated guided vehicle systems.

The gradual digitalisation of German industry is giving rise to a number of challenges, particularly in the mechanical engineering sector. Companies need to ascertain what effects the digital revolution will have on their traditional fields of business and how they can translate these effects into future business models. Digital engineering is an area that could help the mechanical engineering sector benefit from digitalisation both in terms of in-house processes and the interface with the customer.

But isn’t the mechanical engineering sector digital already? After all, 3D data and CAD are already indispensable.

Thanks to engineers’ innovative prowess, the mechanical engineering sector has always picked up on trends or even set them. But digital engineering is much more than just using CAD and 3D data as a sort of island solution. It opens up opportunities to network engineers and their projects – far beyond what currently passes for project engineering. 

This concerns, for instance, the extent to which digitalisation can help integrate upstream and downstream tasks and processes such as production and after-sales service into an engineer’s workflow. The opportunities in this regard include interdepartmental collaboration and optimisation with the help of entirely digital processes. 

Is the potential increase in process efficiency really worth the necessary investment in infrastructure?

The term “Industry 4.0” sometimes scares people off, as they often don’t fully grasp what it means in practical terms for their business. Every mechanical engineering company will reach a different conclusion as to which strategy and measures are appropriate and cost-effective for them. 

You don’t always have to devise a master plan to make significant improvements and achieve greater efficiency. Just choosing the right partner and integrating small, appropriate tools often helps to efficiently derive practical advantages from digitalisation. And given the shortage of skilled workers in Germany, you simply can’t put a price on the added value gained by implementing carefully thought-through interdepartmental processes. 

What else in particular should mechanical engineers watch out for in relation to those points?

Using the current options available through digitalisation to combine and adapt individual processes is no sure-fire success. Companies need to make a conscious strategic decision before they can start to enjoy the benefits we’ve discussed. This is where employees undoubtedly play a key role – they need to be brought on board and kept on board because their working processes will change. Senior managers need to monitor these changes and developments to assess the associated opportunities and risks. 

The opportunities in particular need to be made very clear to employees. At the heart of it all, digital engineering is about efficiently interlinking standard processes. The time saved allows employees to focus on value-adding tasks, such as the actual design and engineering work. If companies manage to clearly communicate such advantages, employees will automatically be more open to changes affecting established processes.

What is the best way to communicate digital engineering within a company?

From an employee’s perspective, efficiently linking standard processes ultimately means no longer having to carry out unnecessary repetitive tasks. The item Engineeringtool, for example, offers smart functions for automating numerous steps in 3D engineering. Another important aspect is the digital transfer of data within the process chain, which eliminates the cumbersome task of re-entering data by hand, such as when ordering components for a construction. 

What’s more, automatically transferring data removes the risk of employees re-entering it incorrectly. Despite clear-cut benefits for the workforce, it is important to talk about the benefits that digital engineering offers the company, too. Ultimately, that means being transparent when it comes to communicating the importance of a digitalisation strategy for the future of the company – and therefore for the safety of employees’ jobs.

How exactly will digital engineering improve mechanical engineering processes in the future?

The mechanical engineering sector of the future will not be based solely around the classic concept of selling machinery, but will generate more sales from services related to machinery, such as predictive maintenance and plant optimization. Having constant access to a backed-up online archive containing the entire project history and real-time coordination with customers on site offer added value in this regard to further develop the business model. Digitalisation can also make it considerably easier for several engineers to collaborate on the same projects and share project information with the customer easily online without the need for special CAD readers. 

Will this give rise to new business models, too?

If you take a look around at the leading trade fair in Hanover, you will notice that more and more machine manufacturers are turning into software developers. The companies that manage to win over customers with a combination of hardware and software or even tap into new fields of business will take the lead in the era of digitalisation. The high-performance item Engineeringtool already enables our customers to turn the advantages of digital engineering into an edge over their competitors. Our goal is to actively shape the future of mechanical engineering by utilising our more than 40 years of experience in developing innovations.

Literally setting the scene for every theatre performance, backdrops are essential. But, the practical solutions used to perform seamless scene changes shouldn’t be underestimated either.

Even if you exclude state-funded companies and opulently equipped city playhouses, the theatre scene in Austria is thriving. One of the most striking examples of that is the project conceived by actors and theatre producers Nikolaus Lechthaler and Rosie Belic. Their private Lechthaler-Belic theatre (Le-Be) in Graz champions humorous high-brow pieces and characteristically understated staging. The theatre has been based in a lovingly renovated former bakery since 2008, has a seating capacity of 80 and features a stage measuring 6 by 6.5 metres. Until now, the theatre has used wooden constructions in its stage technology. However, when a new production arrived that requires very frequent scene changes without the aid of coverage from the curtain, an alternative had to be found. 

A very “dramatic” challenge 

“I had the idea that a carriage could travel in from the wings to change the backdrop,” explains Lechthaler. But the theatre’s very tight budget was not the only limitation in the search for a solution. On the one hand, stability was essential, as the scenery has to carry the weight of the actors without disrupting their performance. On the other hand, there were personnel issues to consider: “We build everything ourselves and don’t have any handymen or specialist stage hands,” explains Lechthaler. Following the recommendation of a sponsor, the theatre initially considered using a steel solution for the stage technology. However, it soon became clear that would be impractical, as they wouldn’t be able to take the system apart as they wanted to. After a few twists and turns, the same contact helped make the connection with the Graz branch of our Austrian distribution partner, Haberkorn. 

Alfons Wernig, head of the profile systems workshop at Haberkorn, immediately spotted the potential and paid a visit to the Lechthaler-Belic theatre, which is famous among the city’s residents. It quickly became clear that two seemingly unrelated areas – technology and theatre – actually make the perfect pair. Naturally, the personal touch also played an important role, as Lechthaler explains: “We simply found we were on the same wavelength. We achieved a lot that day.” Wernig couldn’t agree more: “Everything just slotted into place. And, after all, it isn’t every day you get the chance to build something in the workshop that will be seen by so many people.” 

Stage technology builds a bridge between two worlds

During performances of the successful French comedy “Trennung auf Bestellung” (Dump on Demand) written by Tristan Petitgirard, theatre-goers are regularly amazed: “That’s impossible! Where did that come from?” In the darkness of the theatre, the stage rolls in from the side, framed by spotlights and naturally with an actor on board, all in line with the brief. Nobody in such a small theatre expects to see anything like that. The secret to this spectacular and effective performance is a roller guide with chain drive (Linear Unit LRE 8 D14 80x40 KU 80) that has been engineered and built as a mobile stage. 

The stage itself is also made from item components. The stage trolley can be moved continuously in both directions on its undercarriage, meaning that the stage appears with a movable structure and then disappears into the side structure shortly thereafter. The system has also been designed so it can be folded to the side at any time. The project was a real highlight for Wernig, too: “It was a great opportunity to see how enthusiastic our staff are. My team even did the planning and building work voluntarily and in their own time.” The team from Haberkorn oversaw the project and carried out maintenance work so that the audience could enjoy the performance without any unexpected high drama from backstage hitches. Further joint projects are already being planned.

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

“The cubes” were the centre of attention at the Solingen Güterhallenfest art festival. Ten cubic frames built with item profiles were created to frame the artists’ installations.

For more than ten years now, the art festival known as “Güterhallenfest” has been a true institution in the Solingen arts scene. Every year, the artists’ colony based in the warehouse of Solingen's old central rail station invites members of the public to the two-day event. This year’s festival, held on 12 and 13 May with the slogan “2.5 cubed – packed in a box”, was another complete success. Visitors had the chance to venture into the warehouse’s forecourt and admire outdoor art installations displayed in ten cubed frames, which were 2.5 by 2.5 metres in size. Spread across the field, these cubes made for a rather unusual exhibition. Behind it all was our Profile Tube System D30. It’s no secret that we attach great importance to promoting young talent and art and are fascinated with all sorts of design. 

Impressive cubic presentation

item profile technology has already shown itself to be ideal for building trade fair stands or even pieces of furniture – but using it to “frame” a work of art is something entirely new. The cubes, which formed a narrative through the exhibition space, were originally going to be built from roof battens. But the organisers quickly came across a much more user-friendly solution. “Thank goodness item then offered to provide us with their building kit system profiles, which we used to create our frames,” says artist and spokesman Peter Amann.

The underlying idea is as simple as it is effective. Each artist decorated one of the ten cubes in their own unique style to present their installation and creative interpretation in the best possible light. Special requests such as cross profiles were no problem at all – the artists were free to let their creativity run wild inside the cubes. As evening fell, things got even better, as an impressive light installation drew the visitors’ eyes to the cubes yet again.

Sturdy – all thanks to item

While building the cubes, item staff were on hand to give the artists all the support they could and to make sure the frames were constructed properly. The Profile Tubes, Angle Brackets, Fasteners and, in some cases, double profiles from our Lean Production Building Kit System ensured the cubes were stable and secure. Our user-friendly and quick-fix fasteners really showed what they were made of – the artists were astounded at how easy it was to build the frames with item solutions. Without any instructions, one participant started tinkering about with the profiles and was amazed at how simple and effortless the whole assembly process was. Even festival visitors showed their appreciation for the unusual presentation of the artworks. 

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

The requirements in specialist mechanical engineering are tough. But what exactly does that mean when it comes to quality and service? 

Whether you’re talking about a lean production assembly cell, ergonomic assembly workstations or even a protective enclosure for a laser used to track space junk, week after week on the item blog, the stories and views of our interviewees all highlight the most important rule in specialist mechanical engineering – rigid concepts never get you where you want to be. Instead, what lies at the heart of this extraordinary and fascinating sector is creativity and a flexible approach to both design and execution. That in turn means that the components used in specialist mechanical engineering applications have to satisfy some very specific requirements. But what kind of problems do specialist mechanical engineers typically encounter in their day-to-day work? And how can they get around them? 

Broader definition of quality and increased time pressure 

These days, the concept of quality covers much more than just the resilience and durability of the materials used. In fact, it encompasses everything from the system as a whole to all the processes that are linked to it. Added to that is the growing importance of lean production principles – companies are working hard to avoid tying up capital unnecessarily. That means they aim to manufacture and hold in stock only as much as is strictly necessary. Or, to put it another way, they only start manufacturing something once an order has actually been placed. For that approach to work, both the product and the entire system behind it must be flexible and top quality. That even stretches as far as comprehensive customer support, and manufacturing companies should focus on elements such as one-to-one assistance, help with technical and design issues and rapid, reliable delivery. 

Time is another key factor in specialist mechanical engineering. Of course, it goes without saying that time efficiency has always been incredibly important, whether in terms of project milestones or delivery deadlines. Nonetheless, manufacturing companies have since come under much greater pressure. In fact, time pressure is growing constantly, with companies in many sectors now having to routinely agree contractual penalties for significant delivery delays in order to secure orders. Customers are also becoming more demanding when it comes to flexibility. New requirements profiles are coming thick and fast, meaning that plants have to be reconfigured and modified increasingly often. One of the primary challenges in specialist mechanical engineering is helping customers to improve or redesign their production systems at ever-shorter intervals.

Maximum requirements for materials and customer service  

We have always tackled these specialist mechanical engineering challenges by putting in place our own quality and service policies. There are numerous reasons why purchasing item components represents a sustainable investment in the future. This is ensured by meticulous and continuous quality management certified to ISO 9001:2015. Our solutions are extremely robust, durable and flexible and all products are put through intensive testing in prototype engineering. They also incorporate safety factors that are geared to the product and user. This flexibility goes above and beyond what is expected of a modular aluminium building kit system, with even the very first original components in the MB Building Kit System still in use and available for delivery. What’s more, these hardy originals are still 100% compatible with the very latest item product innovations – and the many more yet to come. 

This kind of continuous availability and forward-looking approach are particularly important in specialist mechanical engineering, as is maintaining an unwavering focus on the customer. Our motto “Your ideas are worth it” really shows how much we value our customers. The sales and manufacturing centre we opened in the Piepersberg business park at the end of 2016 has further enhanced our customer service offerings. This is reflected in our promise to deliver in-stock goods within 24 hours to customers in Germany and customised components within 48 hours. Construction kits and ready-made turnkey solutions can be delivered within 14 days, depending on the scope of the project in question. Some 5,000 continuously available small parts, 1,500 metric tons of lengthy products and 120 panels – those are the key stats for the storage facility that ensures the availability of the item product range. We also do everything we can to make it easier for our customers to complete their projects. Whether one-to-one consulting and sample solutions, training courses or practical software for digital engineering, we’re always there to help.

Want to keep up to date with everything that’s going on in the world of item? Simply subscribe to the item blog by completing the box at the top right!

How directly comparing feedback data offers an important insight into the benefits of digital solutions.  

The non-profit FIR e.V. institute at RWTH Aachen University has been conducting interdisciplinary research and training for over 60 years. The aim of the institute, which is also a member of the Johannes Rau Foundation, is to investigate and teach methods that bolster economic growth and boost employment rates. The FIR teaches its students key skills for the networked company of the future – at a time when industrial digitalisation is high on everyone’s agenda. To pass on its expert knowledge and foster cross-sector dialogue, the FIR hosts all manner of events, including practical workshops, specialist conferences and working groups. One of its workshops looks at the best way of capturing feedback in industrial assembly operations.

Impressive findings thanks to small Lego cars  

Feedback data in this context means the time taken to pick materials or carry out certain processing stages. That’s why workshop participants – who come from the industry – are asked to perform assembly tasks at work benches from item and keep track of the time they spend on them. These particular item work benches are preconfigured designs. On top of the L-shaped legs are columns that are combined with cross bars to mount material containers, barcode scanners and Pivot Arms for the computers. It wasn’t just high quality standards that convinced Moritz Schröter, deputy production management director at the FIR, to opt for item solutions: “Our top priority was authenticity, as we were set on creating a realistic environment. And item is simply the industry benchmark. Besides that, we needed a solution we could put together ourselves – it was the perfect choice.”

As mentioned above, the aim of the workshop is to find the most efficient solution for assembly work at the standing workstations and then think about and discuss the respective pros and cons of the different approaches. “The participants start off by creating three different variants of toy cars with Lego building blocks as per the plans provided,” explains Schröter. The first workstation is where parts are removed from storage containers and orders picked. The Lego vehicle is then assembled at the four following assembly workstations. Each of the individual steps in the whole process is recorded and tracked based on feedback data. 

Experiencing and assessing industrial digitalisation under real conditions

Schröter and his team have devised a three-tier process to compare the different methods of time tracking. In the first tier, participants record the data on paper and later enter the information into a computer. “This method tends to be imprecise. It’s easy to forget to jot things down, so there’s a risk that the subsequent computer entries will be incomplete,” Schröter points out. 

The second tier uses barcodes on the order papers that each need to be scanned. The time that each barcode is scanned into the system indicates the status of processing and/or the end of processing. The third tier utilises the NFC tags on the bottom of the material boxes, which are registered at each work bench by special readers. “Essentially, the processing times are recorded simply by virtue of the materials being present at the various work benches,” explains Schröter. As a result, the participants don’t even have to pick up a barcode scanner. 

Innovation at work 

Besides this digital method of capturing feedback data, the workshop uses a whole range of other solutions that demonstrate the potential of industrial digitalisation. Specially developed pick-by-light technology, for example, is used to ensure participants at the first workstation know which container they need to pick from next, and the assembly guides are also fully animated. There is even a voice input option for acknowledging individual picking operations. The next step planned is to use analysis software to identify irregularities in the feedback data. The learning environment is funded by the Walter Eversheim Foundation.

Want to keep up to date with everything that’s going on in the world of item? Simply subscribe to the item blog by completing the box at the top right!

How the right support can help break down old-fashioned hierarchies and stereotypes. 

It goes without saying that women are just as capable as men in technical working environments. The Massachusetts Institute of Technology (MIT) is a prime example of how targeted encouragement and personal support are key to women entering the engineering job market. Taster events and tailored advice offer a clever way to dispel the reservations that many women and girls have about working in science and technology when they leave education. Last year, an impressive 49.5 % of all mechanical engineering students at the institute were women. This just goes to show how important female role models can be – and Fabiola Calderón couldn’t agree more. Much like her American colleague KJ Cocke who we introduced two weeks ago, Calderón works at item and speaks about her personal experiences for the Advancing Women Engineers initiative. Born in Mexico, Calderón works as an industrial engineer at item Oeste México and was greatly inspired by her own role model.   

How to keep disabled workers and their skills in the business.

We are all unique. That seems pretty obvious, and it is especially relevant in specific areas of the working world – and yet it is a fact that is still sometimes overlooked. Manual industrial work is one of these specific areas. To ensure workers perform well and can maintain healthy posture at the same time, work benches need to be adjusted precisely to their specific needs. Appropriate ergonomic principles are even more important when it comes to disabled employees. Accessible and disability-friendly work bench design perfectly counterbalances physical impediments regarding aspects such as height, handling area and lighting. A present-day example of how work bench systems can support long-serving employees can be found at Bögra GmbH in Solingen.  

Decades of expertise 

Bögra is a specialist manufacturer of rod bushings and piston pin bushings in die-cast copper alloys with a history reaching back more than one hundred years. Established in 1913, the company was named Böntgen & Grah following Eugen Grah’s decision to join founder Max Böntgen. It didn’t take the business long to build up a workforce of 60 employees. After 1945, the manufacturer decided to close ranks with the automotive sector, which remains one of its most important partners today. 

At the same time, the company started to venture abroad and consequently expanded its product portfolio. The focus shifted from pre-turned to ready-to-install slide bearings. Gravity die casting parts, continuous casting parts and combination bearings were added to the product range. After restructuring in 1992, the company was renamed Bögra (a portmanteau of Böntgen and Grah) and, the following year, staff moved into a 1,200 m2 production facility. It is in no small part thanks to continuous technological additions, such as the introduction of semi-automatic casting machinery for gravity die casting in 2011, that the company has seen its customer base continuously grow.  

Disability-friendly work bench design takes the strain 

Owing to various health problems, an employee in the dispatch department has restricted mobility and is unable to reach very far. As he is responsible for weighing individual components and heavy cartons of up to 30 kilograms, movements that typically form part of his job would have caused him serious pain. Lifting heavy cartons and holding the same position for long periods of time would have been particularly strenuous. A cutting-edge solution was needed that could provide a customisable dispatch work bench so that he could carry on working. That’s why Bögra opted for our Work Bench System. During the planning stage, managers from both Bögra and item met with the employee on several occasions to hash out the details. 

The result is a disability-friendly work bench comprising an electrically height-adjustable table frame with a table top featuring recessed scales. The staff member can now take the goods in a comfortable posture and move them onto the table – all without having to use a great deal of strength. Depending on requirements, he can now also work standing up or sitting down. Comfortable reaching distances and contemporary power and data supply are ensured by two Drawer Units, a Tray with an Angle Locking Bracket, a cable duct and a Keyboard Arm. What’s more, additional equipment such as a label printer can be positioned perfectly within the employee’s reduced handling area. Thanks to his new accessible work bench, he can now work extremely productively and take care of his health at the same time.

Are you interested in ergonomics and accessible solutions that break down barriers? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

Young female engineers should not be discouraged by outdated clichés.

While some still believe that engineering is a man’s thing, it is evident that times have changed, as shown by events like Girl’s Day. Demands for gender equality and diversity were able to change significant parts of the working world fundamentally. But there is still room for improvement. Our dear colleagues at item West in the US started the project “Advancing Women Engineers“ in order to encourage more women and introduce them to engineering. Here strong women speak about their motivation and give advice on how to overcome long-lasting prejudices. No question, this is something we support enthusiastically. In general, fairness and respect for every individual have always been very important for item. We begin with KJ Cocke who works as an engineering manager at item West. 

Female engineers ensure more diverse products 

KJ Cocke believes that a balanced workforce is vital in helping engineering firms produce products that meet the diverse needs of their customers. “No matter what field you’re in (within) engineering, end-users are both men and women, so there should be equal representation in creating products for them,” Cocke notes. “Whether it’s a cart in a plant, or an iPhone, or a child’s toy, both genders should have collaborative input on creating those things.”

Although the number of female engineers today has greatly improved since the early 1980s, when only 5.8% of engineers in the U.S. were women, it’s still surprisingly low. Currently, only 14% of engineers are women, according to the Congressional Joint Economic Committee. “Women have a lot to offer to this industry — our point of view, our own intelligence, our own perspectives,” says Cocke. “If we choose to sit out of those opportunities, or choose to let (lack of) confidence or self-esteem get in the way, we don’t get a say, an influence, or a chance to impact a product.”

The small portion of women in US engineering

According to The American Association of University Women, the United States will need 1.7 million more engineers and computing professionals by 2027. So, if engineering is such an attractive career path, why is there such a large gap between the number of male and female engineers? Cocke believes attitudes that girls encounter early in life have a large impact. “I think it has to do with the ‘intimidation factor’, in large part,” she says. “A lot of girls start to lose their self-esteem in sixth or seventh grade when they begin making personal connections and finding their place in the world, and find it’s not ‘cool’ to be smart.”

She believes this kind of stigma has a pronounced social effect in the way that girls develop their interests from that point forward, and the way that they interact with their male counterparts who have similar interests. “It makes them feel this competitive edge” Cocke notes. She believes that many girls then begin to wonder how they can be “as good” as the boys. “In reality, you don’t have to be ‘as good’ as the boys … you just need to be as good as you,” she says.

Things women in engineering should do 

Cocke recommends empowerment and resilience for women who either currently work in engineering fields or who hope to someday pursue a career in engineering. She has a few words of advice for women who are contemplating this career path: “Be ready for those challenges, because there are men who may not take your opinion seriously,” she cautions. “There are going to be people who think you don’t belong in that career, but that’s not true. You have just as much right to be in that career as any other person in the field.”

She believes these negative attitudes can be overcome with preparation and by consistently producing high-quality work. “Be confident,” Cocke encourages. “If it means you need all the more facts (and) knowledge to prove yourself, you’ll work twice as hard … and your peers and supervisors will see that.” Cocke believes that, ultimately, women’s success in engineering is a matter of persistence. “I think we just need to be empowered, to be present and to participate,” she says. “Don’t let anyone crush your spirit to create something for the future!”

Want to keep up to date with everything that’s going on in the world of item? Simply subscribe to the item blog by completing the box at the top right!

Water is a serious business at RWTH Aachen University.  

Research at the renowned Institute of Hydraulic Engineering and Water Resources Management at RWTH Aachen University covers a wide range of topics. Whilst hydraulic engineering focuses more on the structural side of things, water resources management looks at the usage and conservation of bodies of water, taking the associated risks into consideration. The Institute has changed names a few times over the years, but has existed ever since RWTH Aachen University was founded in 1870. Professor Holger Schüttrumpf has been Head of the Institute since 2007. Some six years after taking up his post, Schüttrumpf and his colleagues moved into new premises.  

Blowing other labs out of the water 

The new building features an integrated laboratory covering an area of 2,250 m². One piece of equipment found in the laboratory is the “Nelli 2” survey boat. The catamaran’s flooring is made of a seawater-resistant aluminium alloy, but we’ll come back to the topic of aluminium later. All in all, the new laboratory enables researchers to conduct experiments with watertight materials on an even larger scale. For example, there is a three-metre-high model dyke containing plastic mats with sensors that provide information on movements. There is also a 400 m³ tank underneath the floor of the lab that combines with an elevated tank (constant water head of 7 m) and a DN400 ring main to generate water circulation with a flow rate of 1,200 l/s. 

An elegant solution for special requirements 

Over the course of their various experiments, the researchers regularly need to machine watertight materials to exact dimensions. To do so, they use a panel bending machine in the lab, the basic frame of which is made with profiles from our MB Building Kit System. Head of the model construction department Manfred Kriegel, who has worked at the Institute for over 40 years, explains how it works: “To put it in simple terms, you have to imagine the machine has a 1.2 mm long wire in the middle, which is heated to 150 degrees. When material such as plastic or plexiglass is laid over the machine, the area directly above the wire heats up.” The plastic is used to build water channels, for example. 

Once it has been treated in this way, the material becomes soft, like rubber, at the point where it has been heated and can be shaped as required. For example, it can be placed against an angle bracket so that it takes on exactly the same shape as the bracket. The key advantage is that you can warm up specific parts of the plastic separately. Of course, you could also put plastic into a mould and then heat the whole thing up in an oven, but then you’d have to work with a panel that was soft over its entire surface area. By contrast, plastic treated using the panel bending machine only becomes soft exactly where you want it to, and the surrounding material remains unaffected. The alternative approach using an oven carries the risk that side areas could also become deformed.

Well ahead of the competition 

Having used a competitor’s material in the past, the Institute of Hydraulic Engineering and Water Resources Management opted for our water-resistant profile technology. One of the many reasons they decided to switch was the quality of the material, as Kriegel explains: “At item, no matter where along the groove you insert a T-Slot Nut, the thrust piece holds it in place. If I have a vertical profile, the T-Slot Nut naturally stays exactly where I want it.” The avid researcher also appreciates the “exceptional versatility” of our profile technology. That’s why the Institute now also uses item Hinges in its models’ weir doors, which are used to regulate water levels. 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

The methods and tools of lean production have been a popular topic on our item blog for quite a while now. They show us how successful process optimisation can be implemented in production. Not only that, concepts such as CIP or the PDCA cycle can be highly useful outside the factory environment, too – just as lean management has proven. Our colleague Thomas Hytzki is the go-to man for any theoretical and practical questions about the lean methodology. Readers who are new to lean production are sure to find our interview with him an eye-opening experience.      

Lean production – a fascinating challenge 

One-piece-flow alone isn’t enough 

The choice of material is decisive for lean production 

Industry 4.0 and process optimisation in production 

Why ergonomic principles are important, even in the digital future. 

As we enter the era of digitalisation and Industry 4.0, the same questions keep cropping up time and again. Will the human worker be soon replaced by digital colleagues? Is the ‘smart factory’ a place where processes are dictated by networked machinery? It’s understandable to think these things but there’s no reason to be afraid. Our cognitive capabilities mean robots or algorithms are no match for us in many areas of work – and it will stay that way. And if you also take complex, motor-controlled processes into consideration, this becomes even clearer. But some things remain uncertain. What will the industrial work bench of the future look like? What effects does Industry 4.0 in production have on ergonomics and employee welfare? 

The golden opportunity of digital transformation 

One thing is for sure – traditional mass production will soon be a thing of the past, as it is gradually being replaced by series production of customized individual pieces. Intelligent networking of all stations within the value-added chain aims to achieve flexible and customized production of a batch size of 1. For this to succeed, the processes upstream and downstream of production have to continuously exchange data amongst themselves and with all stages of the production process. This will help provide an early means of preventing coordination errors caused for example by material delays at the work bench. 

Fears that the industrial working environment will dramatically change are unfounded, however. The individual worker will undoubtedly have to come to terms with new technologies. In the context of digital transformation, the concept of lifelong learning is on everyone’s lips. But that doesn’t mean we need to fear for our jobs. Existing aspects – including ergonomics, customization and modularity – will become increasingly relevant. Companies need to concentrate on these aspects to maintain an attractive place to work for future generations and ensure success for years to come.

Ergonomics is anything but ready for the scrap heap 

Ergonomic aspects continue to play an important role in work bench design. They help boost employees’ productivity and health in equal measure. Individualisation of the work bench is a key aspect in this regard. An ergonomic work bench system offers the perfect foundation for ensuring manual production processes become more effective in the future. A case in point are height-adjustable work chairs and tables, which can be adjusted perfectly to any given body type. Transforming a standing work bench into a sitting one (and vice versa) is easily done, too. What’s more, the customized positioning of materials and tools avoids uneven physical strain. 

It’s often overlooked but no less important – the right LED or natural lighting helps boost concentration levels and thus reduce the risk of errors. To top it all off, a modular work bench system can be seamlessly adapted and expanded to keep up with the increasingly mechanical world of work. There is relatively little effort or downtime involved. Monitors, for example, can be mounted in an ergonomic position or cables and wiring can be safely stowed away in cable ducts or conduits. Pivoted monitor arms ensure everything is organised in a precise and customized fashion to avoid unnecessary physical strain. Screens should always be placed in the worker’s field of vision, not to the side. 

Industry 4.0 in production – an advantage for ergonomics

Demographic changes and the increasing average age of workers in Germany are highlighting the importance of ergonomics. Companies are keen to ensure their ageing, highly qualified workers are healthy and productive for as long as possible. After all, ergonomic work bench design is also a preventive measure. Industry 4.0 in production should be seen as a way of easing the burden on employees because, despite the growing trend of automation, even the future can’t get around manual assembly tasks. 

This is where collaborative robots come into play. Their job is to take over strenuous working processes, such as lifting and positioning heavy workpieces, from employees who directly interact with the robots. Deploying collaborative robots also calls for particularly stringent safety procedures. The risk of a potential collision between humans and machinery must be kept to a minimum. Cyber-physical systems (CPS) are used to support human workers, too, and also serve as a means of storing information. The mechanism can autonomously decide which employee, based on their physical build, is a suitable choice for the next working stage and who should take a break. 

Are you interested in ergonomics and what the working world of the future will look like? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

How it all began: From two-man firm to worldwide success story. 

A new sales and production centre in Piepersberg, the recently opened item site in Hanover (which is also home to our Lean Factory) and not forgetting the innovative developments in digital engineering – a lot has happened at item in recent years. So it seems like the perfect time to take a minute and look back at the history of the MB Building Kit System. After all, besides being fun, delving into the past can teach us a lot, as company timelines such as ours often show just how profitable a long-term outlook can be. For item, it all started in 1973. Gerrit Pies and Wolfgang Rixen became friends whilst working together in the design office of a renowned mechanical engineering company. Not long after that, the two perfectionists decided to set up their own design office. Back then, the two-man company was still named “Rixen & Pies GbR” but unofficially everyone was already calling it “item” – an abbreviation of “industrial technology and mechanical engineering” in German. 

Starting out in Solingen

In their very first office on a small street in Solingen, Pies and Rixen could often be found toiling away late at night. During the day, whilst one continued working as a design engineer, the other set about putting together quotations and drawings. At the heart of it all, item began as many start-ups do today. It didn’t take long before the partners made a name for themselves as designers and engineers of their independently distributed specialist machinery and in 1976, the company was officially renamed “item”. 

Two years later, the business relocated to new premises with an on-site assembly workshop in the north-west of the city. New recruits joined the team and the company was more determined than ever to make its specialist machinery even more versatile and efficient. item was quick to adopt a workstation from Siemens, including a monochrome monitor and dot-matrix printer, and used it for all business correspondence, invoicing and order processing. The electrical engineering department was equipped with the latest technology, too, this time in the shape of programmable logic controllers (PLC). 

The inspiration for the MB Building Kit System 

It was one of those strange quirks of life that saw the company get serious about aluminium for the first time: Another passion of the two founders – cycling – led them to acquire a brief to develop and produce a bike rack primarily built from aluminium components for a customer. item had the necessary material produced in an aluminium press shop. As the project developed, the founders gradually realised the potential of the extrusion process. They experimented and created Profiles 40x40 and 80x40, which would later become the basic profiles for the MB Building Kit System. The new screw attachment principle using the aluminium building kit system profiles revolutionised the process of building expensive and time-consuming steel frame constructions.

The time for a universal profile system made from aluminium had finally come. The first version was launched in 1980. To begin with, experts were sceptical about the idea but the form and functionality of the system – comprising initially seven basic profiles, a number of fasteners and functional elements and the first accessories – quickly won them over. As all constructions could be continuously adapted and, where required, redesigned from scratch, the system was already fully compatible with the then-new CAD technology. With its modular design, the MB Building Kit System laid the foundations of digital engineering.

Growing success abroad 

item concluded its first distribution agreement for the MB Building Kit System with a partner company back in 1984. At the start of the 90s, item began successfully collaborating with distribution partners in Hungary, Slovenia and Poland. Then, in 1992, the first wholly owned subsidiary outside Germany was set up – item Italia. item continued to bolster its position on a regional scale, too, and founded eight distribution centres for the MB Building Kit System. Today, this figure stands at eleven. Slowly but surely, item became a global company – the USA was added to the list in 1997, followed by Australia and Africa just two years later. Nowadays, item solutions are available on all five continents. Besides setting up wholly owned subsidiaries in Switzerland and Poland, subsequent milestones notably include opening item International America LLC and item China. 

Want to keep up to date with everything that’s going on in the world of item? Simply subscribe to the item blog by completing the box at the top right!

Sometimes it’s the ideas that seem weird that ultimately produce the most fascinating results.

Those were the days – if you grew up in the 1990s or had children at the right age back then, you’re bound to remember having crazy water fights to cool down during the summer holidays. No sooner were the Super Soakers and other water pistols brought out than you were good to go! However, try looking for a modern equivalent that combines the fun of days gone by with the latest technological advances and you’ll be disappointed, as there have unfortunately been no notable developments in this field – quite the contrary. Sebastian Walter, who previously worked as a product designer in the automotive sector, came to the same conclusion. The fact he refused to give up and pursued his dreams shows, however, that we have a lot to learn from the start-up scene. 

Starting shot for a career in the water pistol business 

In light of this gap in the market, it didn’t take Walter long to decide what he had to do and he forged a plan on how to create a better product. Together with a software and electronics expert, he began developing the first prototype for the water pistol of the future. Just a short time afterwards, the two friends successfully applied for support from the Start-up Incubator of the Strascheg Center for Entrepreneurship at Munich University of Applied Sciences. Besides offering financial aid, the Start-up Incubator also gives entrepreneurs practical assistance and a space where they can tinker about undisturbed. 

The result of their hard work is the “Spyra One”, referred to by its founders as “the water pistol for dads”. What makes this innovative water pistol stand out is that it doesn’t just shoot one long jet of water but fires lots of small spurts, as the valve only ever opens for a split second. Targeting your opponents is therefore easy – and completely harmless. Only tiny amounts of water are used, with each shot releasing a maximum of 40 ml. The Spyra One offers an experience that is less like traditional water fights and much more like playing laser tag or paintball, although players don’t need expensive specialist clothing or a controlled environment to have a good time. After all, the entrepreneurs’ vision has always been to create a product for spontaneous water fights in the park on a summer’s day.  

Cutting-edge technology for summer fun 

Production of the Spyra One has not yet started, but the prototype alone is highly impressive and already fully functional. To create the prototype, the Spyra team created a basic frame built using the MB Building Kit System and attached the remaining parts, which were made by a 3D printer using rapid prototyping. This is where our stable yet flexible aluminium profile technology had particular advantages to offer, creating a foundation that held the other components, including the integrated electronics, firmly together. Spyra actually came into contact with item by chance, but you could say it was destiny. Among the other start-ups using the facilities of the Start-up Incubator is the Formula Student team, municHMotorsport. Given that we have been a long-standing supporter of this exciting university sport, as many of our readers will know, it didn’t take long before our MB Building Kit System came up in conversation. 

The kickstarter campaign is just around the corner 

After using our profile technology to good effect for the first time, it wasn’t long before the next project came around, when we helped the team build test equipment. The structure in question is made from aluminium profiles and is enclosed on all sides with acrylic glass to create a kind of corridor where individual “shots” can be observed to determine how they behave, looking at how far the water shoots and how big an area they hit. 

The team of passionate entrepreneurs at the start-up has gradually grown. Marketing expert Rike Brand is overseeing a playful promotional campaign for the Spyra One on Facebook, for example. Summer 2018 will be a crucial milestone for the start-up. This is when the team will begin a 30-day campaign on the crowdfunding platform Kickstarter, where the high-tech water pistol will be available to pre-order across the globe. Anyone interested in the innovative gadget can help finance production by pre-ordering the Spyra One on Kickstarter and will then be one of the first customers to get their hands on the water gun in spring 2019. We’ve got our fingers well and truly crossed and look forward to discovering more innovative products from this fantastic start-up in the future!

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

How the Faculty of Building Services, Energy and Environment is using an intricate structure to simulate wastewater flows. 

Esslingen University of Applied Sciences was formed when the University for Technology and Esslingen University for Social Studies merged in 2006. Just under 6,100 students at eleven faculties are currently working hard for their future under the guidance of 224 professors. Numerous results in university rankings are testament to the quality of teaching. In 2016, for instance, the university came in third place for mechanical engineering in the ranking by German business magazine, Wirtschaftswoche. The Faculty of Building Services, Energy and Environment offers two exclusive degree programmes – a Bachelor’s in Building Services, Energy and Environmental Engineering and a Master’s in Energy and Facility Management. In view of the current energy revolution, these programmes have real potential. But it’s not all about theory, as students have the chance to get hands on, too, and this is where item comes into play. 

Seven metres for an in-depth insight into practical applications 

One of the pioneering projects at the faculty is a new laboratory featuring an elaborate wastewater tower. The tower offers students an authentic insight into exactly how water flows in a normal household behave. There is a facility designed to replicate a toilet flush, a bath tub is simulated and there are various washbasins and sinks. The process of building a sanitary system provides a practical way to show students the careless mistakes that are to be avoided when constructing wastewater systems. Having previously used our profile technology to good effect, e.g. when building test frames for certifying toilet flush mechanisms, the decision to use item solutions was a no-brainer for the university. The TPS Stairway/Platform System and Line 8 profiles were used for the project. The former allows users to access the frame on two levels. 

Lots of challenges, ideal material

Although the material for the wastewater tower was machined and delivered to the university back in autumn 2013, it took quite a while before building began as delays to the construction of the laboratory meant having to wait almost three years. During that time, however, building requirements had changed and, as a result, parts of the wastewater tower – including the stairways and platforms – needed to be returned to the item site in Ulm. Luckily, the modular nature of the material ensured modifications could be completed quickly. 

Optimum laboratory for the energy revolution 

The laboratory, which covers an area of 1,400 square metres and features 35 laboratory test benches of all kinds, was officially opened on 30 June 2017. Laboratory facilities were previously spread across the campus but now everything is in one place. The aim right from the start was to create an inspiring learning environment that combines the best of theoretical and practical training. This approach is reflected in the very design of the building, which not only houses laboratories, but can even be studied as a research subject in its own right. 

For example, the entire IT infrastructure, including the energy monitoring technology and building automation, are a showpiece for the students. Last but not least, what makes the new laboratory so special is its sustainability. It generates more energy than it consumes thanks to, amongst other things, its own solar plant on the roof. This commitment to the environment has already been commended with the “sustainable building” certification by the German Sustainable Building Council (DGNB). 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

To promote the upcoming Trials World Cup in Berlin, cup coordinator Frank Drygalla is touring the German capital with a bike show – and a whole host of item solutions.

The challenge for Frank Drygalla’s trial bike show was to design an obstacle course that fits into a car boot. The solution is a course built using lightweight, quick-to-assemble and flexible item profiles. Drygalla is now using the solution to promote bike trials, a relatively young form of cycle sport. The first competitions in Germany were held in the mid-1970s. This October, Berlin is playing host to the UCI Trials World Cup 2018. When he’s not busy organising the Trials Cup in Berlin, Drygalla works as a mechanical engineer. As a result, he is very familiar with the advantages of a wide range of materials and 3D engineering is part and parcel of his daily work. When his intriguing proposition landed in our inbox, we didn’t hesitate to pledge our support to the project.

What are bike trials?

Trial cyclists need to demonstrate balance, strength, concentration and endurance. They have to tackle a range of obstacles on a lightweight 20 or 26-inch bike, usually without a saddle and suspension. How? Riders jump, hop and try to keep their balance – sometimes only on the front wheel, sometimes on the back wheel. “In principle, it’s height that makes all the difference, which is also the tricky part,” explains Drygalla, who knows a thing or two, having initiated several trial bike shows already. The obstacle course is not just designed to test competitors, it also delivers captivating viewing for spectators. 

It all comes down to not touching the floor – if you do, you lose points. There are five different sections to complete. The objective is to stay on the track, which is marked by arrows or gates. Cyclists are eliminated if they put both feet on the floor or if they rack up more than five penalty points.

Developing a trial obstacle course

In addition to the standard wooden pallets, tree trunks and concrete blocks, aluminium is also a perfect building material for a show trial course, which naturally has to be stable and secure. When designing a section, trial organisers usually draw on their many years of experience. All the same, when they have sufficiently stable materials to work with, they can let their imagination run wild. As an engineer working with Line 8 from item, Drygalla was able to unleash his full creativity: “Many cyclists look for systems that they can set up relatively quickly for an obstacle course in the show area, and are really interested in materials that can be used for that purpose.”

The obstacle course planned for the show area needs to be flexible and lightweight. The cyclists tour a variety of locations, both indoors at large and small trade fairs and outdoors in parks. “You can obviously also use pallets to build the obstacle course, but it usually doesn’t look as good. item products just make it look more professional and much easier to set up. They’re also easy to transport and that’s exactly the major advantage that item offers,” says Drygalla. 

Trial bike show – variable thanks to item

The UCI Trials World Cup is taking place in Berlin from 13 to 14 October 2018. Before the event kicks off, the organisers are on tour with their item obstacle course. Anyone interested in taking a look at this relatively unknown sport therefore has the perfect opportunity to do so at one of the trial bike shows in Berlin: 

Berlin Bicycle Week (20-25 March 2018)

VELO Berlin (14-15 April 2018) 

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

With the Engineeringtool from item, you can work on your next project intuitively from anywhere and without the need for any additional software.

Modern mechanical engineering processes are becoming increasingly digital. Looking back at blog posts from the past year, item MotionDesigner^® and item MotionSoft^® for our item linear motion units^® and the practical item Machining Tool are just two examples of how digital engineering speeds up day-to-day project work. Integrated filters and tools take care of complex calculations and make it easier for users to select the right components. The item Engineeringtool is another important step in this direction, adding a considerably wider range of functions and combining the familiar online configurators from item into one engineering solution. Our goal is to create a digital workstation for all engineering tasks that use item components. Digital engineering with item will make your work faster and easier. 

What the item Engineeringtool can do

The first version of the item Engineeringtool is compatible with all components featured in our MB Building Kit System. Profile technology from all item lines can be used for free, rule-based engineering. 3D engineering tasks can be completed in all modern web browsers, with no need for any additional software. Engineers anywhere can use any end device with Internet access to easily create basic constructions that can be equipped with the appropriate fasteners, Caps and floor elements directly in the item Engineeringtool.

Its easy-to-use functions include integrated product finders, a drag-and-drop function for the easy placement of components, and the automatic alignment of parts. When fasteners are placed on a design, the software also performs an automatic plausibility check and incorporates all necessary profile machining, meaning engineers can carry out frequent standard tasks quickly without having to use a CAD system. What’s more, the item Engineeringtool makes design and configuration easy for almost anyone, without the need for extensive induction training.

CAD data and project documentation included

The core concept of the item Engineeringtool is to make 3D engineering with item components possible even for those without their own CAD system. Worldwide unique project numbers mean you can also share your designs with colleagues across the globe. CAD data output options even allow you to easily transfer your projects from the item Engineeringtool to your usual CAD environment, where you can continue working on them. 

Our approach to digital engineering gives you everything you need to reduce throughput times for engineering tasks. Use the item Engineeringtool in meetings to sketch out projects right in front of the customer. Define your project enquiries with ease using our efficient end-to-end 3D engineering solution and compile comprehensive project documentation for your designs at the touch of a button.

Why wait? Try out digital engineering with item!

3D engineering, CAD export and project documentation are not the only benefits of the item Engineeringtool, however. With just one click, you can convert your construction into a shopping cart and place your order directly online. The item Engineeringtool gets you on course for the future of mechanical engineering. Check out the clean and clear interface that enables you to efficiently perform engineering tasks and discover the opportunities available by digitalising order and production processes. Your ideas are worth it!

Want to keep up to date with everything that’s going on in the world of item? Simply subscribe to the item blog by completing the box at the top right!

5000 submissions from 56 countries, 45 awards – and item took home one of the coveted gold trophies.  

Our solutions have always stood for excellence in functionality and design. This consistent commitment has also resulted in numerous design awards. Naturally, gold awards are a particularly special honour, and item has just added to its collection. On 7 February, the German Design Awards 2018 were handed out amidst the buzz of the Ambiente consumer goods trade show. The item team headed by designers Carsten Schulz and Stefan Mostert were presented with the German Design Award Gold for the operating elements Pi range. The range includes Knurled, Wing and Tri-Lobe Hand Knobs and Handles and combines a simple design language with ergonomic principles. Products in the Pi series of operating elements also each come in three sizes and two colour variants to open up a wide range of potential applications. 

A tradition that demands top performance 

Each year since 2012, the prestigious German Design Awards have celebrated products and brands from Germany and beyond for enriching the design landscape through innovation. Behind the awards themselves is an institution that has continuously shaped the story of design in Germany since it was set up on the initiative of the Germany government in 1953 – the German Design Council. It pursues the same main aim today as it has done since its establishment – strengthening the German economy from a design perspective. One particularly important guiding principle throughout its work is to boost brand value by making strategic use of design. 

Aims and challenges

Although item has long been supplying high-quality and ergonomic grip solutions, the operating elements were usually products from standard parts suppliers. Although these elements fulfilled their purpose, they left some room for improvement when it came to our claims regarding contemporary design. We were particularly focused on the haptic characteristics of the elements – after all, it’s vital to have the virtues of operating screws and grips quite literally in hand. These elements are among the first things users touch when they come across a new plant or construction, so the clear aim was to introduce our own operating elements to further improve those first impressions. 

The operating elements Pi range also had to work in perfect harmony with the components from the MB Building Kit System and Line X. One of the most striking features of the latter is its clearly accentuated design. The choice of two colours for the primary components, which can be combined with Caps that are available in two colour options, opens up a range of design opportunities. At the same time, the classic item design language runs through all the products. The statement released by the judging panel for the German Design Award praised the fusion of form, function and user-friendliness. The “fantastic holistic approach” was singled out in particular for exhibiting “an aesthetic quality that is exceptionally high by industrial standards” and “coherent product semantics”. 

Working as a team to secure the German Design Award 

The project was a perfect example of the value that item places on the synergies that emerge from inter-departmental collaboration. Every single phase in the working process was shaped by close and continuous coordination. The company’s combined expertise was made readily available at every point in the development process, and everyone involved worked together efficiently. A dedicated SLS 3D printer provided additional support for coordinating efforts. This meant prototypes that were close to series-production standard could be manufactured rapidly to test out and improve ideas. 

Injection-moulded plastic components normally have thin walls so that high-quality surfaces can be achieved on the side that is on view. However, this poses a challenge, since users’ hands tend to completely envelop elements such as these when using them. This means the reverse sides also have to have a high-quality surface in order to present consistent high-end standards. Thanks to their many years of experience and close cooperation with the supplier, our team came up with a solution. The elements are designed as sealed, single-piece articles but are not made with expensive or complex injection moulding technologies using internal gas pressure or multiple parts. 

We’d like to thank the designers involved, Carsten Schulz and Stefan Mostert, and Benedikt Weiss and Anna-Katharina Krieger for the technical support they provided for the project. 

Want to keep up to date with all the exciting innovations from the world of item? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

Aluminium profile technology can also be used in interesting projects at home.   

Previous blog entries have tended to focus on unusual uses for item solutions, and there have certainly been plenty of those – from a protective roof for tomato plants and a table-tennis table right through to a composter and a door displaying family photos. This demonstrates both the wide range of applications our aluminium profiles support and the creativity of our staff. We recently found out about two more interesting home improvement projects. Both deal with typical challenges that will be familiar to many homeowners.   

Perfect protection for your scooter 

Determined to protect his scooter from icy weather conditions, an item employee came up with the idea of building a motorcycle garage. However, with only a small space available on sloping ground, using a ready-made shed from a home improvement store wasn’t an option. The only solution was to build it himself from scratch. By using Line 8 profiles from item and weatherproof plastic panels, he was able to tailor the structure perfectly to the site. He chose Profiles 8 40x40 light with closed grooves for the sides and painted them green.

He attached the roof to the sides at a 5° incline with mitre fasteners. Assembled using Profiles 8 40x40 and heavy-duty universal fasteners, the roof can carry even high snow loads. A small truss also helps to stabilise the load-bearing surface of eight square metres. Hinges 8 Al and Door Lock 6-8 Zn were used for the 1.4-metre-wide door. Thanks to this protection, it’s also being used to keep various garden appliances safe and dry alongside the scooter. 

Partying with profiles  

Another item employee has been working on a different, but no less exciting, home improvement project. Since he was having a new house built anyway, he couldn’t pass up the opportunity to install a basement party room with all the classic fixtures and fittings. Basement party rooms may have been more on-trend in 1980s Germany, but they do have something of a cult status. The proud homeowner took lots of inspiration from his work as a customer adviser, particularly when it came to deciding on the look. He had Line 6 profiles from the MB Building Kit System cut to size and then got to work building a bar. 

The end result is outstanding – the combination of aluminium profiles and panel elements made of satin-finished, opal-tinted Acrylic Glass create an elegant minimalist look. Partygoers have been highly impressed and there is a surprising amount of space, with drinks on the left and all the tech on the right. But there is always room for improvement, something we have learned from the continuous improvement process. The bar is fully functional, but will be subject to a few optimisations.  

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

For a long time, specialist mechanical engineers welded together steel to make their frames. 

Gerrit Pies and Wolfgang Rixen, the friends who established item, came up with a ground-breaking idea – screws instead of welds, aluminium instead of steel. The underlying belief was that steel no longer met the growing needs of specialist mechanical engineering. What started off as playing around with aluminium profiles developed and used strictly in-house, ultimately became a comprehensive system. The 1980s saw the beginning of the successful modular MB Building Kit System. But what specific advantages do aluminium profiles actually have over steel in specialist mechanical engineering?  

Aluminium profiles – first-class material 

The advantages of an aluminium profile system start with its basic material properties. Aluminium is much lighter than steel but still extremely strong. Corrosion doesn’t pose much of a threat to it and there is no need for time-consuming protective measures.  As a result, two typical cost factors related to steel, i.e. regular maintenance and applying corrosion protection, are irrelevant. Aluminium is also very easy to shape whether hot or cold, is exceptionally conductive and can be produced via extrusion.  

Saving time and money in specialist mechanical engineering

When using aluminium profiles in specialist mechanical engineering, there are only three processes to complete – sawing, screwing and assembling. These steps can all be carried out by a single mechanic without the need for additional training. What’s more, there is no need for special equipment or a large range of machinery. Companies retain constant and full control over the timing and quality of the work as they don’t need to rely on external suppliers. In addition, a building kit system with aluminium profiles ensures the engineering process runs smoothly. Necessary adjustments that only become noticeable during the manufacturing process can be rectified in a few simple steps thanks to innovative fastening techniques. Subsequent customer requests for changes and alterations can also be implemented within a very short time.

By contrast, even simple steel constructions can require up to eight steps – sawing, machining, fixing, welding, cleaning, priming, coating and finishing. This has further consequences, as the more process steps there are, the greater the likelihood of errors. Processing steel therefore inevitably involves numerous intermediary stages which, according to the 7 Muda of lean production, are considered wasteful. Outsourcing individual processes means having to check the quality of external work, which costs more time and money. Ultimately, the low procurement cost of steel should not be considered in isolation.  

Aluminium profile technology makes transportation easy 

Steel frames make systems very heavy and, because the frames cannot be easily dismantled, also rather cumbersome. In logistics, these are two significant cost factors. When it comes to large objects, it is not uncommon for the space and layout of the customer’s premises to change at short notice between the planning and implementation stages of the project. Thus, the only option is to partially disassemble the project, which is a costly process. 

The lightweight properties of aluminium, however, offer many direct advantages when it comes to transportation, since heavy trucks and other expensive means of transport are not required. The modular concept of an aluminium building kit system also has a direct effect on transport and subsequent processes. During transportation and assembly, the added flexibility that comes from being able to make rapid adjustments during unloading, moving and installation on site really pays off. Preassembled elements, for example, can be dismantled before transport and easily put together again once the project has reached its final destination. 

Want to keep up to date with all the exciting innovations from the world of item? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

The Czech Republic’s passion for motor driving knows no bounds.

We’ve already reported on the exciting Formula Student competition twice before, when we went behind the scenes to meet the racing teams Ecurie Aix (RWTH Aachen University) and Campus Motorsport (Hannover University). Now the competition is proving highly popular in the Czech Republic, too. One of the country’s many ambitious teams is VŠB from the Technical University of Ostrava (Vysoká škola báňská – Technická univerzita Ostrava) – a team that certainly isn’t afraid to put its foot down. But the race cars aren’t just judged on their speed and technology. Points are also awarded for how teams showcase design and business concept. This is exactly where our valued distribution partner for the Czech Republic and Slovakia, Haberkorn, stepped in. Thanks to their support, the ambitious young race drivers can go full throttle.  

Brilliant minds with various specialisms

Although the Technical University of Ostrava was the fifth technical university to sign up to Formula Student, it was really just a question of time. It is undoubtedly one of the best places in the country to study engineering. Before its transformation in 1904, the technical university was previously a mining academy. Over the course of the Czech Republic’s eventful history, it performed well and continued to grow. Innovative minds at its seven faculties devoted to research and development secure a high number of patents. 

Right from the start, the focus has been on promoting a lively exchange between research and business. Nowadays, the university even boasts a successful start-up incubator. Passion, an interdisciplinary approach and an openness to new things – these are the ideal qualifications for participating in Formula Student. It’s no wonder that numerous faculties are putting their heart and soul into the competition. That’s also why it appeals not just to mechanical engineering students, but to students on business, material technology and metallurgy courses, too. 

Haberkorn and item offer their know-how for Formula Student

Given the Formula Student team’s ambitions and capabilities, it was a perfect fit for a collaboration with Haberkorn. With the Technical University of Ostrava only 30 minutes’ drive away from the Haberkorn office in Mokré Lazce, cooperation between the two was made even easier. The initial task was to create three display boards that are needed, amongst other things, to present ideas to sponsors in the pit lane. Once the material had been prepared by Haberkorn employees, it was the students’ turn to have a go. During a tour of the Haberkorn site in Mokré Lazce, they had the chance to get to know some of our products. 

Students were particularly impressed by the flexibility and light weight of item profiles. Both aspects are of vital importance for an international competition that involves a great deal of travel. It was then time for them to put together their display boards, which they built using Line 8 profiles from our MB Building Kit System. Last year, the team also used a transport trolley to bring tools quickly and securely to the pit lane. Due to time constraints, Haberkorn employees built the trolley, using Line 5 profiles. The students used all their free time for the fine tuning of the race car. We wish them much success and fun for the upcoming races!

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

2017 proved a particularly eventful year for the CETPM, an institute at Ansbach University of Applied Sciences, with a new campus building opened in a very short space of time.  

The CETPM, located in the town of Herrieden, Germany, has been the No. 1 destination for lean training courses and events focused on operational excellence and process optimisation since 2005. The institute aims to support experienced industry employees who are eager to learn how they can make processes in their businesses even better. To achieve its aims, the CETPM offers a wide range of seminars, workshops and publications, including a Karakuri seminar with our lean expert Stefan Armbruster. The spacious facilities at the new campus in Herrieden provide the perfect environment for teaching and learning. 

Don’t lose hope, take the initiative!  

The CETPM was previously situated in rented buildings. However, the landlord’s plans changed and the institute had to move out. Looking back, Professor Constantin May, Academic Director of the CETPM, rightfully refers to a “time-critical situation” for the institute, which is renowned for its lean training courses. Staff didn’t let the situation get them down though, and the end result was anything but a “needs-must” solution. The outcome of four months of planning and ten months of construction was a completely new campus building. 

Comprising a total of eight seminar rooms, the CETPM houses 190 staff and students. It also has its own manufacturing workshop – a unique feature for a (lean) training institute – where course participants receive first-hand instruction in lean production in a teaching factory. In fact, the CETPM has been working closely with item in precisely this field since 2011. “We are leaders in lean management and item is a leading company in work bench design – it’s a great match,” says May. Amongst other things, students at the teaching factory must learn how to design an assembly cell based on lean principles. Until recently, however, there was one big problem. The expertly crafted constructions had to be dismantled at the end, meaning visitors to the CETPM never got the chance to see the ideal solutions in all their glory. At the new campus, however, there is now enough space to display an optimum example of an item assembly cell. 

Karakuri meets Industry 4.0 – how lean training courses should be  

The assembly cell is located in the “Lean 4.0 lab”, the highlight of the newly constructed building complex. At the heart of the cell is a Karakuri solution from item, which the company helped create with the item MB Building Kit System. Karakuri is often referred to as low-cost automation or simple automation and is a form of automation that doesn’t use electrical drives or sensors. “It’s about solving automation problems not with money and high-tech, but with the intelligent ideas of on-site workers – that’s Karakuri,” says May, neatly summing up the underlying principle. A tablet-based order management system is also used in the cell. Each work bench has its own tablet to register working steps and take photos or videos of any problems. 

The photos and videos are then sent to the team leader. This equipment is supplemented by a material supply system using low-cost AGV (automated guided vehicles), which means materials can be moved quickly and easily from the warehouse to the assembly cell. This smart interlinking of simple automation and digital technology is rounded off with 3D printers, which supply the assembly cells with customer-specific attachments. “Digitisation isn’t as simple as blindly using any type of software or hardware. The first step always needs to be process optimisation. Only once that is done do digital elements really make sense,” concludes May. 

Are you interested in fascinating reports and innovations from the world of lean production? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

It’s never too early to get practical experience. This is particularly true in lean production – after all, efficiency improvement has to be learnt. 

That’s why the Chair of Production Metrology and Quality Management of the Laboratory for Machine Tools and Production Engineering (WZL) at RWTH Aachen University is now offering a voluntary practical course in lean assembly as part of a series of events entitled “Industrial Assembly Systems”. Students discover first-hand what really matters when planning lean assembly systems, most importantly in terms of dividing up tasks and organising sequences. During a timed exercise, two six-person teams go head-to-head at the five stations of a lean production assembly cell provided by item. Who can faultlessly organise and complete the assembly of our popular FIFO dogs? But that’s not all there is to it. Senior Engineer Guido Hüttemann, who leads the course, says: “Bad decisions and the impact these have on planning are an integral part of the course. Learning from your own decisions is a vital part of practical training.” 

An eye-opening challenge 

The practical lean course is held in the WZL assembly workshop. There’s a real hustle and bustle, with innovative constructions everywhere you look. On entering the shop, you can’t miss our assembly cell on the left, which is arranged in a U shape with the individual stations interlinked by roller conveyors. Each station has small load carriers, into which the students have to place materials, and a whiteboard for displaying illustrations of the parts to be assembled. The actual assembly work is done on an assembly plate which, thanks to the roller conveyors, zooms from station to station so that the relevant assembly stages can be completed one by one. 

The participants get real hands-on experience in lean assembly. Students are given all the tools and aids they need, of course, such as parts lists and design drawings for the variants of the dog that are to be assembled. Then it all comes down to their aptitude and organisational skills. After getting in some practice by disassembling a completed FIFO dog, the students analyse assembly times, establishing a standardised organisational principle by considering questions such as: Which steps take place at which station and in what cycle time? 

How do transport times between the stations impact assembly? 

Lean assembly and more 

Pre-assembly isn’t permitted – the interns can only get to work once the official starting shot has been fired. After all, there is no preferential treatment in the real world of production. But these realistic conditions are exactly what makes the experience so valuable for the students’ future. For Hüttemann, the entire practical course is a form of exam preparation: “Those who plan and carry out the assembly themselves get a hands-on experience of the difficulties involved. They also get a very clear understanding of lean production and its benefits.”

He and his team are already looking to the future, with plans to host a two-day workshop that will see the assembly cell “updated”. Initially, students will build a modular, semi-automated assembly system and subsequently take over the assembly planning for a specific project. The final stage will involve packaging the FIFO dog, supported by an industrial robot with corresponding controls and the evaluation of images from a 3D camera. What is also of particular interest for students is the integration of a web application for use in assembly planning, – a good example of how lean production and Industry 4.0 complement each other perfectly. 

Are you interested in fascinating reports and innovations from the world of lean production? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

The meaning behind lean production terminology.

Lean production concepts continue to be successful, whether applied directly in industrial processes or in a slightly modified way in lean management. But for those new to the topic, the numerous and by no means self-explanatory terms can easily be confusing. At first, the various abbreviations and/or Japanese technical terms may seem uninviting. If you take a closer look, however, you will discover fascinating and logical ideas for process optimisation. In this blog post, we aim to give a compact overview of the main lean production methods. 

The continuous improvement process (CIP) 

The continuous improvement process (CIP) is at the heart of all lean production methods and is based on the concept of “Kaizen”, transferring it into an industrial context. This key Japanese term is made up of the words for “change” (Kai) and “for the better” (Zen). Accordingly, continuous improvement processes aim to provide a working environment which openly accepts mistakes. If something isn’t running smoothly, it is perceived as an opportunity to improve rather than a reason to get annoyed. 

It is important to note that CIP isn’t aimed at major errors but often at small details because, let’s be honest, nothing is perfect. In this respect, CIP aims to hone everyone’s senses and employee participation is vital to achieving this. Employees observe processes first-hand right where they happen, the place referred to in lean production as “gemba”, and are therefore in the best position to judge where there is still room for improvement. You only need to look closely.  

7 Muda: Avoiding waste 

A further fundamental principle of the lean methodology is that if you want to optimise your own processes, you need to actively tackle waste. In Japanese, “Muda” refers to a useless activity in the sense that it does not help to create value. According to the 7 Muda, waste can be avoided in the following ways: 

• Don’t move materials around needlessly
• Reduce warehouse stock
• Avoid movements that are not ergonomic
• Cut down on avoidable waiting times
• Simplify processing
• Continuously improve 

The above list clearly demonstrates how closely intertwined the individual lean production methods are. The 7 Muda provide key approaches to recognising areas in need of continuous improvement. With that said, you also need to know how to tackle waste in practice. Merely recognising the different forms of waste is not enough. 

Using the 5S method to establish standard processes 

Whilst CIP remains rather abstract and provides the conceptual framework, lean production methods such as 5S show what is vital in practice. The 5S method serves to standardise processes to ensure a designated output within a designated timeframe and with 100% quality. For example, 5S establishes stable processes that help to reduce throughput times. In addition, standardisation creates a basis for continuous improvement. Toyota employee Taiichi Ōno once said: “Without standards there can be no continuous improvement.”

5S owes its name to the individual words that make up the method and which each begin with an “S” in Japanese: 

• Seiri: Remove everything that is not needed. 
• Seiton: Set up working material ergonomically and label it. 
• Seiso: Always clean your own workplace and do so thoroughly. 
• Seiketsu: Clear up regularly to prevent disorder.   
• Shitsuke: Always be disciplined.  

There are numerous benefits to successfully implementing 5S. Besides increasing productivity and quality in assembly, using working spaces more effectively and maintaining a tidy workspace will generally also boost employee motivation. You can arrange your next customer visit at any time, without any nasty surprises.  

Are you interested in fascinating reports and innovations from the world of lean production? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

The festive season is just around the corner, so it’s the ideal time to pause for a moment and look back on events in 2017. We’re also signing off for a short Christmas break. 

Back at the very start of the year, we reported on a spectacular extension. The Piepersberg site, which opened in December 2016, is our new sales and production centre. Combining a storage and production area of around 21,000 square metres with 2,800 square metres of office and showroom space, it’s highly impressive and its main aim is to provide an even better service for customers. Whether opting for standard delivery or electing to pick up their orders themselves, customers benefit significantly from the pooling of expertise at one location and excellent transport links.

Pioneering vinyl pressing and underground laser 

Vinyl records are a real collector’s item for many music fans, so the “Pioneering vinyl pressing” blog proved particularly popular on Facebook. Following a retrofit to modernise an existing record press, item pluspartner Irmler from the German region of Lower Saxony successfully tackled the challenge of building a machine from scratch. The new press combined decades of tried-and-tested record technology with heating cycles controlled electronically using a PLC and state-of-the-art drive technology. Due to its sheer size, everyone was talking about the European XFEL – the world’s largest X-ray laser – but we had a special reason for a trip into the 3.4 kilometre long tunnel complex. Our Profile X 8 is a successful part of the mobile cleanrooms used there for assembly and servicing work. 

Lean production in practice 

Lean production methods are firmly established in industry, but further information is still required. We took a closer look at the PDCA cycle with the aim of making the continuous improvement process (CIP) even clearer. The lean concept can be implemented with a kind of checklist using the four process steps “plan”, “do”, “check” and “act”. Our interview with Stefan Armbruster about Karakuri Kaizen provides a seamless link with this practical aspect. The lean expert underlines the benefits of low-cost automation. Automating straightforward, repetitive tasks takes the strain off employees while also boosting value creation. Götting KG’s automated guided vehicle system for SMEs is a fascinating example of how our Karakuri intermediate store can be put to good use. 

Digitalisation provides key impetus for the world of work 

“The item Machining Tool – the fastest route to the finished profile” was an excellent example of the extent to which digitalisation simplifies work processes. Time-consuming steps used to be inevitable for anyone requiring profile technology with the associated connection processing. With the item Machining Tool, however, all individual steps are combined in one overarching process that includes 3D view, project documentation and ordering. 

Symbiosis of form and function 

The second half of the year provided not one but two examples of the versatility of our Profile Tube System D30. The first comes from our own workshop, where our innovation department built D30 racks suitable for homes on a trial basis. The second is the task faced by renowned Spanish designer Tomás Alonso of developing pop-up stores for the Rapha cycling sport brand. A material was needed that combined extremely high quality and flexibility with stylish aesthetics. Alonso found the ideal combination of form and function he was looking for with the Profile Tube System D30. The black version of the profile, internal fasteners, wooden elements and black-and-white photographs reproduce the atmosphere of a cycle race. 

We hope that this year, too, we’ve been able to offer you interesting blogs about solutions, applications and people from the world of item. We’d like to wish all our readers, customers and partners a very happy Christmas and a great start to the new year! We’ll be back on 10 January next year with our first blog for 2018.

The breakneck speed of baseball places huge demands on the equipment used for games and training sessions. 

Baseballs can easily be thrown at speeds approaching 150 kilometres an hour. Although the hitter and pitcher officially stand 21 metres apart, there is often only around half this distance between them during training sessions or when warming up. If the hitter makes contact with the ball and it speeds back towards the pitcher, it can pack a huge punch. The purpose of L-screens is to prevent injuries when such short distances are involved. The pitcher stands behind the vertical part of these L-shaped frames for protection. When the L-screen being used by the Sehnde Devils gave up the ghost, the item branch in Hannover insisted on helping to make a new one. Unsurprisingly, this L-screen was produced using a unique special design. 

Anything for the club 

Baseball may have been usurped by American football as the number one sport in the United States, but Major League Baseball is still extremely popular. Japan, too, is so enthusiastic about baseball that it has become a national sport there. Baseball leads something of a niche existence in Germany, but that does nothing to dampen the fervour of the German baseball community. This is particularly the case with idealistic players who sacrifice their free time to their local team – and the Sehnde Devils are just such a club. In 1995, in only their second year, they were already playing in the district league and in the very next season they won promotion to the regional league. However, the fact remains that funds are limited in the amateur game. 

Sometimes, a little bit of good fortune is required. Devils player Alexander Schellbach happened to be at the Weyersberg baseball ground in Solingen with his wife when the team we sponsor – the Solingen Alligators – were playing the Paderborn Untouchables in a Baseball-Bundesliga game and he got talking to the stadium announcer. “I knew how much item does for baseball, so I had a little chat with him about sponsorship,” recalls Schellbach. When the new branch in Hannover opened shortly afterwards, contact was quickly established. 

Not your usual L-screen, but one with a meshed design 

Armed with a few illustrations of typical L-screens, the Hannover engineers got to work. The design is based on our MB Building Kit System, with a special protective mesh to stop baseballs in their tracks. Final assembly took place at the club with three players from the team. Schellbach was surprised by the end result. “I’d assumed the new L-screen would be far heavier than the old one, which was made out of PVC tubing and was slightly smaller. But I was wrong because the new one is very light and easy to transport,” he says. 

Nonetheless, the L-screen got through its first training session with flying colours. By the time the new season starts next year, if not before, it will have become an indispensable part of the safety equipment during pre-game warm-ups. Any changes that happen to be needed can be made in no time at all thanks to the flexible modular design. A horizontal profile could be added, for example, and individual sections could easily be adjusted. What may well be on the cards is the addition of castors to create a mobile L-screen. For the time being, though, everything is going fine. “We couldn’t have imagined a better L-screen,” says Schellbach with a great sense of satisfaction.

Do you want to keep up to date about the wide-ranging activities of item? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

The year is fast drawing to a close, which means it’s once again time to make some New Year’s resolutions. 

Many people put health at the top of the list – and rightly so – but there’s no need to overdo things. As is so often the case, it’s small but fundamental changes that make all the difference. At work, it’s easy to end up spending long periods in the same position and placing uneven strain on your body. This is precisely where ergonomic principles can help rectify the situation. Many industrial and other staff aren’t sure about the best place to start, though. To make life easier, we’ve put together ten practical ergonomics tips for you. 

Practical tips for ergonomic working practices 

Whether working in manual assembly or other areas, we now spend hour after hour sitting in the same position. Humans aren’t really built for that, though. We’ve only been sitting for long periods for around 250 years. It quickly takes its toll, causing tension and – all too often – pain. Straightforward but effective exercises can help, especially if you’re not able to take advantage of a sitting/standing workstation. Stretching parts of the body such as the calf muscle, the back of the leg and the lateral muscles of the torso eases cramping. 

You can download our ergonomics tips here for free without registering:

Best of all, these ergonomics exercises aren’t simply intended for staff working at an ergonomically designed production work bench. They can be used by anyone who wants to counteract the negative effects of being in the same position for long periods day after day at work. You’ll find everything you need at any standard office desk, but we’ve also got a range of tips for working at an industrial work bench. Our ergonomics FAQs cover the main points you should bear in mind when it comes to tool stowage, work chairs and work bench lighting.

Are you interested in work bench ergonomics? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

Aluminium in the fast lane – how know-how from Solingen and Spain is delivering virtual racing thrills. 

Racing at breakneck speed through stunning countryside with a foot resting casually on the accelerator – the challenges and experiences in the everyday life of a racing driver are truly captivating. And, thanks to the ingenuity of the entertainment industry, you don’t even need a car to get an idea of what it feels like. Racing simulations are a yardstick for the latest technological advances. That was true in the days of the iconic arcade games with built-in steering wheels and it is still true today, with inventions such as virtual reality headsets continuously pushing back the boundaries of technological progress. Simtechpro from Barcelona is among the pioneers on the racing simulation and virtual reality scene. So why exactly did the innovative Spaniards decide to use our MB Building Kit System? Read on to find out!  

From a racing simulator for the home to virtual reality

Simtechpro boasts a very wide portfolio, simulating the driving experience of Formula 1 cars, GT vehicles, rally cars and MotoGP bikes and even producing flight simulators – all using special platforms that it develops in house. These platforms are in turn fitted with several monitors to ensure users get a truly intense experience. What’s more, drivers can also put on a virtual reality headset for an even more immersive experience of high-speed thrills. Combining VR and conventional displays also resolves a frequent dilemma – what do spectators who don’t have a special headset do? This dual solution ensures, for example, that passers-by at a trade fair are also drawn in to the high-octane action.  

When it comes to racing simulation, Simtechpro has really made a name for itself thanks to its SimBase and SimLight ranges. While SimBase is intended more for professional applications, SimLight is aimed at ambitious gamers who have enough space inside their own four walls. The key is that both systems are exceptionally flexible because they are built using components from the MB Building Kit System: “We can swap out various components from all models, depending on what is needed. The basic structure from item is also exceptionally stable,” explains Pere Arnau i Rallo, Chief Commercial Officer at Simtechpro. 

Racing simulation with plenty of horse power 

Let’s take a closer look at the SimBase 327 model. The heart of the racing simulator is an exceptionally flexible, modular platform comprising high-quality profile technology from the MB Building Kit System. The addition of matching caps and cover profiles also lends this sturdy platform a suitably sophisticated look. As Arnau i Rallo points out, Simtechpro was particularly impressed by the trio of flexibility, stability and aesthetics. “The basic structure is easy to adapt and very durable, but the aluminium profile also gives it a very cool, technical appearance.” Elegant and minimalistic aesthetics are also what made our Profile Tube System D30 so interesting for designer Tomás Alonso. 

Three 27-inch monitors give users an authentic impression of being behind the controls, and the structure will also support screen sizes up to 35 inches. Different software modules can be used to simulate Formula 1, GT and rally racing, ensuring there is something for virtually every fan of racing simulations. Sliding bars are used as a fast and flexible means of adjusting the cockpit. There are two more elements that help make the experience even more immersive.  For example, the built-in motion system – including shock absorbers – replicates realistic movement to match what is going on in the racing simulation. Drivers who execute rapid manoeuvres will feel it through the seat and in their own body – but without ever putting themselves in any danger. A six-channel sound system also creates an authentic racing experience on an acoustic level. 

Do you want to keep up to date on innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

Having recently shed light on ergologistic^® – the interaction of ergonomics and intralogistics – we’re now going to take a closer look.

Our focal point today is the internal material flow as such. This plays a key role in optimum production efficiency, which means very high demands in terms of up-to-date intralogistics. Despite the Latin prefix “intra” meaning between, intralogistics by no means exists in a secure bubble. It is affected by outside factors and is subject to significant external pressure. Consequently, one cog needs to interlink perfectly with the other – because delays quickly cause problems. In addition to consumption-driven material provisioning/picking and employee involvement, the properties of factory equipment are also key. 

Less waste for a better material flow

To ensure a smooth internal material flow, it must be possible to adapt all intralogistics processes at any time. This flexibility must not, however, negatively affect the stability of the material used. If equipment frequently breaks down and needs to be repaired, this results in costs that are absolutely avoidable – waste in other words. The 7 Muda anti-waste concept explains how to avoid such traps. Simply considering the efficiency-boosting principles of lean production on a methodological level isn’t enough, though. Anyone who is looking to optimise the internal material flow needs to pay specific attention to flexibility and durability in factory equipment engineering.

The technical side of intralogistics 

This leads directly to the core element of modern-day intralogistics equipment – solutions and above all optimisations are quickly achieved with modular profile technology such as the Lean Production Building Kit System from item. One tool is sufficient to make relevant adjustments (to a transport trolley, for instance) while maintaining a constant level of stability. Consequently, the fasteners do not need to be retightened and creep is not a problem either. This dispenses with unproductive waiting times, not to mention potential safety risks due to connections that in the worst-case scenario work loose while in use. Thanks to cutting-edge intralogistics, technical uncertainty can thus be removed from the internal material flow.

Want to keep up to date with everything that’s going on in the world of item? Simply subscribe to the item blog by completing the box at the top right!

A big-name designer is using profile technology from item for pop-up stores on four different continents.

 “Good design isn’t just nice to look at, it also fulfills a purpose,” says Spanish designer Tomás Alonso, describing his artistic approach. This symbiosis of form and function is evident in all the objects he designs, which range from home furniture and exhibition pieces in prestigious galleries and museums to luxury articles such as marble and crystal bowls. As our blog entry on the D30 racks showed, Profile Tube System D30 also combines stylish aesthetics with functionality. Alonso agreed and decided to use it as a basis for showcasing the sports products of a high-end customer in the best possible light. 

A lifelong passion for design 

Tomás Alonso is a true cosmopolitan. At the age of 19, his love of design saw him set out from his home country of Spain on an international artistic expedition. After travelling through the USA, Italy and Australia, he arrived in the British capital. While there, he studied and graduated at the distinguished Royal College of Art. Soon afterwards, he set up his own studio in a former  piano factory in east London, which he shared with five other members of artist’s collective “OKAY STUDIO”, which he co-founded.

The “Tomás Alonso Design Studio” produces minimalistic objects of all types, many of which show traces of one of his main sources of inspiration, Italian designer Achille Castiglioni (1918 – 2002). Castiglioni once summed up his passion for functionality in one simple and concise sentence: “so sophisticated and so simple – that’s what I like!” Alonso doesn’t make distinctions between art and commercial endeavours and creates works for design exhibitions, pieces for art festivals and products for well-known brands. He has completed successful projects for customers including IKEA and Swarovski. Despite his young age, his passion for design has helped him secure numerous awards such as the “2013 Designer of the Year” (AD Magazin, Spain) and “Young Designer of the Year” (Elle Deco Japan) in 2012. 

A top-end cycling sport brand

UK company Rapha and its staff are passionate about cycling. In the space of just a few years, the company, which sells cycling clothing and accessories, has grown from a little-known start-up to a high-end brand in its segment. Its dedication to cycling sport comes through on every level, which is why the global Rapha Cycling Club (RCC) numbers more than 7000 members. Every Wednesday, employees mount their cycles in the morning and head out. The London headquarters also incorporate a club house that showcases cycling all day long. There is even a dedicated, in-house cycle workshop there. 

In view of all that, it’s no surprise that Rapha isn’t content to settle for just “the norm” when it comes to its marketing and how it presents its products at the point of sale. Pop-up stores are an integral part of the company’s marketing strategy. These are the exact opposite of a permanent, bricks-and-mortar shop. Pop-up stores are set up for short periods in empty properties and spaces and rely primarily on word of mouth to attract customers. Another advantage to this approach, besides the low rent costs, is that it offers an outstanding opportunity to test out new markets. The Rapha pop-up stores are a kind of hybrid, falling somewhere between a product showcase and art installation and comprising several structures. 

Flexible and thoroughly elegant pop-up store 

Tomás Alonso was given the task of designing a furniture kit that could be easily assembled and disassembled to become a traveling pop-up store. Due to the fundamentally temporary nature of the shops, the designer faced a number of very unique challenges. “The structure had to be adapted to suit each and every new site, so flexibility was a crucial factor. At the same time, you need material that is both flexible and exceptionally stable,” explains Alonso. In view of those requirements, it didn’t take long for him to choose our Profile Tube System D30 which, as he himself says, impressed him with “its technical properties and streamlined look.” Objects such as tables, chairs and frame constructions had to fit seamlessly into the sales environment. 

There was another factor that appealed to Alonso – “the internal fastener had just been launched onto the market. It was perfect for our needs, as it provided an even smoother look.” Another benefit was that the profiles are also available in a black version. Promotional activities are always tied into brand colours and, since black is the colour of choice for Rapha, the black profile was a perfect fit for the company’s style. Combined with wooden elements and black-and-white photographs of cycling heroes, it helped produce an exciting overall look. For example, a semi-circular seating area was surrounded by large photos to create a cycling live racing area within the store panorama, as well as a cafe area. In fact, the entire pop-up store is designed to allow for flexibility and to create different atmospheres within one space in a very clean, reduced way. 

Do you want to keep up to date about innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

Digitalisation marches steadily on, and yet it still remains pretty abstract to many. However, there are already digital solutions that show where things are headed.  

What does the digital revolution mean for your own day-to-day work? Visions of the future are undoubtedly important, but what really matters is the here and now. Let’s take a look at the practical benefits of digital tools. If you’ve ever planned machining work for profiles, you’ll be aware that it involves a whole string of individual steps. After selecting a suitable profile, you need to choose the right fastening technology and profile machining – not forgetting the project documentation for error-free machining and the actual order, of course. The item Machiningtool can help with all of that, guiding the user through everything, from finding the right product through to ordering the machined profile, thereby taking out a lot of hard work. 

Profile machining software that saves a lot of time 

The practical, web-based online configurator makes these otherwise complex tasks easy to master. Conventional tools such as production drawings and self-explanatory article numbers are no longer necessary. Just one of the many highlights of the item Machiningtool is that it lists all the profiles in our MB Building Kit System. All users need to do when looking for a profile is indicate aspects such as maximum weight or length via the corresponding filters. This narrows down the number of suitable profiles. Load calculators also show which profiles can be considered based on criteria such as profile deflection and buckling. 

That also makes the item Machiningtool perfect for users who don’t need any profile machining and just want to find the best profile fast. Once the perfect profile has been picked, it is presented in a 3D view that can be moved around and scaled as necessary. Fasteners can be added and positioned precisely on the profile via drag and drop, with only feasible solutions showing up. Plausibility checks in the background help avoid errors and ensure fasteners and machining steps are applied only at points where it is actually possible to integrate them. In other words, if you’ve opted for through holes, stepped bores or threaded bores in the item Machiningtool, you can rest assured that connection processing will be problem free. 

Want to keep up to date with everything that’s going on in the world of item? Simply subscribe to the item blog by completing the box at the top right!

TUM students are turning the vision of a high-speed tube transport system for passengers and freight into reality.

American billionaire Elon Musk certainly isn’t short on bold visions for future mobility. Some of them, like Tesla electric cars, are already available for everyday use. Musk’s aerospace company SpaceX won’t only be employing reusable rockets to help reduce the amount of hazardous space junk in low-Earth orbit in years to come. It will also be taking people to Mars in the near future. Very much on the ground but no less ambitious is SpaceX’s Hyperloop project, which will soon see passenger and freight capsules linking urban centres on America’s West Coast at the speed of sound using a similar concept to a pneumatic delivery system. TUM (Technical University of Munich) is one of the frontrunners in a student competition focusing on Hyperloop. 

Hyperloop – hovering at reduced pressure

Hyperloop’s drive concept is based on the technology of maglev systems such as the Transrapid. Electromagnets draw along the capsules while keeping them suspended. At the same time, a vacuum is generated inside the tubes. These two things combine to minimise the frictional resistance acting on the capsules and should enable speeds of 1,200 km/h in everyday operation. A number of research institutes and companies across the globe are currently working on concepts for using Hyperloop technology in everyday applications. In the medium term, Hyperloop systems could thus become an alternative to short-haul flights. 

In getting to this stage, SpaceX has so far been harnessing the innovative strength of universities. Since 2015, it has been running annual Hyperloop student competitions. One of the frontrunners is WARR, TUM’s Scientific Workgroup for Rocketry and Spaceflight. The team currently comprises over 35 students from all kinds of different disciplines. SpaceX started by selecting the 120 most promising designs from over 700 submissions and inviting the teams behind them to a design weekend at the Texas A&M University.

TUM’s successful Hyperloop prototype

In early 2016, a panel of judges shortlisted the 22 best concepts from these 120 submissions to do battle in prototype form just under a year later at a specially designed test track in California. The WARR team was shortlisted along with some prominent rivals, including a team from the Massachusetts Institute of Technology (MIT). Following a number of on-site safety tests, WARR’s Hyperloop was one of only three capsules approved for testing on the 1.25-kilometre test track and promptly secured the title of fastest capsule – with a speed of under 100 km/h.

When the competition resumed at the same location at the end of August 2017, this time with the focus entirely on the final speed achieved, the TUM team’s 80 kg POD II significantly outperformed its rivals. It reached a top speed of 324 km/h, while its competitors once again achieved values around the 100 km/h mark. One key factor in the success of the overall concept was the capsule having its own drive unit with a 50 kW electric motor.

High outlay with an uncertain outcome

In addition to being congratulated in person by Elon Musk, the WARR team also made quite a name for itself and for TUM with its achievement. The high costs associated with building the prototype and entering the competition were mainly covered by high-profile sponsors such as Airbus. At its current stage of development, the full-size WARR Hyperloop pod – weighing 600 kg and with a maximum load capacity of 100 kg – reaches an estimated speed of 350 km/h. But the students have plenty of time to optimise their design before the next event in summer 2018.

Want to stay up to date on innovative engineering? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

From factory equipment and Karakuri accessories to software and the Toolpanel System, autumn brings with it a whole host of innovative new products from item.

Our software solutions also benefit from the modularity for which item is known. The item MotionDesigner^®, which is responsible for selecting and configuring item linear motion units^®, has been extended. Loads and motions can now be specified and combined even faster. The ranking of possible combinations has also been refined. Detailed technical information now makes it possible to assess even more accurately which solution is best for the task in hand. Another new feature is the option of generating a CAD model of the linear unit following its custom design. This can then be downloaded directly. The large selection of possible file formats is also highly practical and means the essential original data can always be used directly for subsequent machine construction.

One tool is rarely sufficient

The new Toolpanel System from item makes for even better industrial work bench organisation. The flat design based on Groove Plate Profile 8 integrates easily into existing work benches, all the more since it also includes the necessary holders. Their components have been optimised for numerous tools, while Groove Plate Profile 8 can be arranged across 19 system grooves. A height of 400 mm and a weight of just 5.2 kg per metre make fitting the Groove Plate Profile onto the work bench even easier. Mounting semi-open fronted boxes or documents is no problem either. 

In addition to this, the compatibility of the Groove Plate Profile extends to all existing products in the Hook and Holder System, Shelves and other custom fixtures. It can also be used for supply trolleys and Pivot Arms. Another benefit of the Toolpanel System is that the easy-to-install elements of the item Hook and Holder System mean users can arrange their workspace flexibly to suit their needs. Key tools such as screwdrivers and spanners are in their proper place within seconds. Holders are inserted into the groove and turned 90°. Components locked in this way can thus be used straight away but also removed again and repositioned just as quickly.

Automation made easy 

There have been several item blog posts about Karakuri. An introduction to Karakuri and an interview with our lean production expert Stefan Armbruster were followed by a report about Karakuri in the automotive industry. In a nutshell, Karakuri or Low Cost Automation (LCA) is a form of automation without any electrical support. Instead, the Karakuri method is based on gravity, muscle power and leverage – for far simpler workflows and optimised processes. This really pays off, generating just 10 to 20 percent of the costs of conventional automation methods. 

Ever-growing demands on lean production solutions mean the products need to act directly on this feedback. As always, item has responded to customer requests and further expanded its Karakuri portfolio. For example, factory equipment and assembly workstations can be designed to be even more efficient and compact using solutions such as steel/synthetic fibre cables and Cable Pulley Wheel D42/D6-12. This ball-bearing pulley developed in-house offers a simple and dependable means of guiding the cable. Ring Bolt D10 M6x45 and additional components enable cables to be secured in a Multiblock or – with the help of a T-Slot Nut – directly in a groove so as to guide parts such as carriages or counterweights along profile frames.   

New components for the traditional system

Additional factory equipment now makes the MB Building Kit System even more flexible. For example, the new Latch secures doors and hatches very conveniently. It comprises two parts – one that is fitted to the surrounding frame and another element with a grip that is fitted to the door or hatch. The compact frame part is secured in the Line 8 groove of the existing frame. As soon as the door or hatch is closed, the grip element audibly clicks into place and the user immediately knows it is secure. It takes little force to release the spring-mounted catch mechanism and open the door again, and the ergonomically designed grip makes the Latch even easier to operate. Latches can be used with Line 8 and 6 profiles and with Clamp Profile 8 32x18. 

Other new components include Cover Profile 8 K/Al to close the Line 8 groove and keep dirt out. Little force is required for Cover Profile 8 K/Al and it is easy to cut to the required length using item Multi-Purpose Pliers. An aluminium finish foil means it looks very similar to an aluminium profile. Another new product from item is Stacking Guide 8 St 80x80-30° for stacking boxes, pallets and trolleys. A centring aid ensures objects automatically move into the desired location, which eliminates incorrect positioning from the outset. In addition, the 30° incline distributes weight over multiple points. 

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

Find out how intelligent software is simplifying the configuration and commissioning of linear technology – and opening up new areas of application.

Over the last few years, the term automation has become a buzzword for trends in machinery and plant engineering. Automation solutions are particularly useful in production, where consistent, precise processes significantly increase efficiency and deliver a constant level of quality. On the one hand, linear technology provides the ideal technical basis for this but, on the other, it has also been the very reason why many companies have decided not to automate a process that seems ideally suited to it. The simple reason for this is that linear technology can only deliver the desired performance boost when it consists of a perfectly customised combination of Linear Unit, Motor, Gearbox and Controller.

The simple way to find the perfect linear technology configuration

There are endless combinations of linear guide and drive technology. Indeed, for many potential users, the effort and costs involved in researching and designing a bespoke solution for a specific application outweigh the advantages of automation based on linear technology. And that is without taking into account the outlay for building, programming, and setting up a programmable logic controller (PLC). This was precisely the issue the development team behind the item linear motion units^© aimed to address.

To ensure automation can be configurated perfectly and, above all, easily, web-based item MotionDesigner^© guides users through the process of creating the best possible configuration of linear technology for their specific needs. For example, the configurator considers the repeatability, on-site electrical supply, and other technical parameters. Other criteria are related to the question whether the solution is destined for use in a highly contaminated environment or very clean conditions.

By specifications about the mounting position and motion profile, MotionDesigner^© can provide a customised recommendation out of the thousands of potential combinations. All that remains is to specify the desired installation position, and the solution can be ordered direct from the online configurator. Alongside the optimised turnkey linear technology solution, the tool also highlights any accessories that could be useful.

Fast commissioning of a customised turnkey solution

The item linear motion unit^© is delivered as a preassembled, ready-to-install turnkey solution. All cables and connectors are colour-coded, making connection quick, easy and safe. Another software solution – item MotionSoft^© – links seamlessly with MotionDesigner^© functions to ensure easy commissioning. This intelligent software leads the user – within a controlled process – through the various steps of putting into operation, checks the entire system independently, and determines the optimum parameter settings for operations. 

All in all, this not only saves a lot of time during commissioning, but using item MotionSoft^© also often eliminates the need for an additional programmable logic controller (PLC) for operations. You don’t need to be an expert to carry out the commissioning process. Since everything interlinks seamlessly, several worksteps are saved and mistakes are avoided, which otherwise cost a lot of time and money.

Camera, action and direct assessment – a thrilling glimpse into the future of ergonomic evaluation.

Day after day, experienced specialist workers bring their expertise to bear in assembly processes. At the same time, working in assembly is notoriously draining. The challenge is therefore to hold onto these valuable workers as long as possible while also maintaining cost-effectiveness. Particular effort must be put into making sure work does not put too much strain on staff over time. This is why ergonomic work bench design has risen to such prominence in industry. An innovative collaborative project between the Institut für Integrierte Produktion Hannover (IPH) and the Institute for Production Systems and Logistics (IFA) at Leibniz University, Hanover, has taken up this issue, addressing the following question: Is there a flexible and budget-friendly way of assessing whether employees are working ergonomically at industrial work benches? This issue is particularly relevant for small and medium-sized companies, as not every employee can have access to an ergonomics coach during their initial training. 

The status quo in ergonomic assessment

Ergonomics for SMEs

Researchers at the German Aerospace Center (DLR) are working on solutions to reduce hazardous space junk and are using components from item.

When dusk draws in, all eyes at the Institute of Technical Physics of the DLR in Stuttgart are often turned towards the heavens. Even though the Sun is still shining in a low orbit around the Earth, it is already dark enough to make effective use of telescopes on the ground. In fact, it is at this time that the copious amounts of debris generated by decades of space exploration reflect the last light of the day, allowing scientists to track them based on elevation and azimuth angles. Scientists can determine the trajectory of a piece of debris to within metres using a distance measurement technique developed by the DLR. The technique is based on how long it takes laser light to travel from the ground to the debris and back again. For this system to work, the DLR uses, among other things, a special structure built using components from our MB Building Kit System.

Space junk – the underestimated hazard

There is certainly no shortage of possible targets for the researchers in Stuttgart. There are an estimated 750,000 items of debris orbiting the Earth at various heights, ranging from a few centimetres across to faulty satellites weighing tons. “Objects measuring 10 centimetres or more that are orbiting close to the Earth at an altitude of up to 2,000 kilometres are particularly problematic. Some 17,000 objects bigger than 10 centimetres have been detected internationally to date,” says Wolfgang Riede, head of the department for Active Optical Systems at the DLR’s Institute of Technical Physics. According to estimates, there are 28,000 of these larger items of debris in total.

What makes space debris on this scale so problematic is the widespread use of low Earth orbits for commercial satellites and manned space travel. Even the smallest items of debris will damage the solar cells of satellites and reduce their performance capabilities. Travelling at speeds of eight kilometres a second, a collision with an astronaut on a spacewalk could have fatal consequences: “The hull of the International Space Station has been designed specifically to resist impacts with space debris measuring up to 1.4 centimetres,” explains Riede. If an impact with larger items of debris is likely and there isn’t enough time for evasive manoeuvres, the only option for the crew is evacuation via the Soyuz escape pod and the abandonment of the 100 billion-euro station.

Network of mobile space junk monitoring stations

To make sure it doesn’t have to come to that, the DLR’s Institute of Technical Physics is developing laser-based ground station technology. According to Riede, this concept has one particular key benefit: “Laser propagation time measurement is 90 percent cheaper than the usual radar-based method of detecting space junk.” However, there is also a down-side to the method – it relies on visual contact with the junk and therefore needs suitable weather conditions.

A dense network of monitoring stations is needed if satellite operators and international space agencies are to be supplied with precise projected trajectories. “The weather is always good somewhere, and gaining maximum coverage of the sky would also boost the quality of projections,” says Riede. The starting point is to find locations with optimum conditions for astronomers, such as the Canary Islands, Chile and Hawaii. In the ideal scenario, these would be extended with more sites located as far to the south and north as possible.

Mobile monitoring stations with protective enclosures from item

To fill in the blank spots in coverage on the monitoring map, the system is also being designed in a version that can be transported. All the necessary technology fits into a 20-foot container with an integrated power supply. In total, the mobile monitoring station weighs almost ten metric tons. Once it arrives at its deployment site, the roof of the container is opened to provide an unrestricted view of the sky for the securely mounted dual telescope within. This comprises one transmitter telescope that emits the laser and another 17-inch telescope that acts as a receiver for the laser on its return.

The laser itself is located in a box underneath the mount for the dual telescope and is routed directly to the transmitter via a coudé focus. Together, the box and mount shield the laser beam from the outside world, so that high-frequency lasers can be used without any limitation on pulse energy. It is inside the box, which is made from Profile 8 40x40 light in black and black anodized aluminium panel elements, that the high-precision laser beam is aligned, which means the area must always be completely free of dust.

Maximum precision to avoid new space junk

The protective enclosure, which the laser cannot pass through thanks to additional accessories from item, satisfies two crucial requirements. Firstly, it shields the laser from outside influences such as weather, excessive temperature fluctuations and dust. Secondly, it ensures people in its immediate surroundings are reliably protected from the dispersion and reflection of the laser beam. “Thanks to the modular design, repairs and corrections can be made to individual elements at any time. This gives us the flexibility we need when working with optomechanical systems,” says Riede, explaining why item components are used so frequently.

In the long term, a network of cost-effective monitoring stations could play an important part in preventing the generation of new space junk. When working with accurately projected trajectories, satellite operators would be able to initiate evasive manoeuvres in good time. Every sizeable collision in orbit increases the risk of a domino effect that could generate a lot more additional debris. “The more time and effort that is invested in avoiding the generation of space junk when planning new missions and preventing collisions, the more easily the problem will be contained,” points out Riede. Once a critical point is reached, costly new processes will have to be developed to clean up the junk-filled lower orbits around the Earth. Until the junk is cleared, the entire area will be unusable for space travel.

Do you want to keep up to date about innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

The term “barrier-free” is used a lot these days, and in all sorts of contexts. But what does it mean for manufacturing companies? 

Sometimes it refers to texts or websites, sometimes to buildings or participation in working life. In those kinds of circumstances, it’s pretty clear that the barriers in question can be both physical and “non-material” obstacles. The German Federal Government Commissioner for Matters relating to Persons with Disabilities summarizes freedom from barriers in the following way: “‘Freedom from barriers’ means full access and unlimited opportunities of use in all aspects of life.” Naturally, that includes barrier-free working in industry. But how do you break down the pretty considerable barriers in this particular aspect of life? And how exactly do companies benefit from using modular barrier-free work bench systems? 

How employers benefit from barrier-free work benches 

Companies can’t ignore the demographic changes affecting society and the persistent lack of skilled workers. They need to take action. By using barrier-free work benches, they can show their vision and take proactive measures instead of just reacting. To start off with, this approach may help net highly skilled and motivated employees who would otherwise often – and through no fault of their own – fall through the gaps in the labour market. According to estimates, by 2021, approximately 3.4 million people with a serious disability will be of working age. Many of those people will be highly skilled. Older employees are also invaluable, not just because their high skill level means they are excellent workers, but because they can also pass on crucial expertise to career starters. 

What’s more, it pays to take into account basic ergonomic principles for all workers, not just disabled and older employees. Ergonomically designed work benches also benefit younger members of staff, who learn to be more mindful. This in turn has a positive impact on their productivity. In an interview with us, Professor Martin Schmauder perfectly summed up the essence of ergonomics and simultaneous freedom from barriers, describing it as a symbiosis of “humanity and cost-efficiency”. Viewed from that perspective, it is worthwhile considering how barrier-free work benches also impact on a company’s image. Indeed, what better calling card could a company hope for than a highly skilled and grateful workforce that commits to the business for the long term and stands for its social conscience. 

Practical tips for barrier-free working

So how should companies go about acquiring barrier-free work benches? Once again, Professor Schmauder has some sage advice. And considering that barrier-free working is based on an ergonomic methodology, his summary is spot on: “Work bench systems based on a building kit system can be used in a whole variety of ways several times over. If a product range changes – which is often the case today – these systems can be adapted and there is no need to buy anything new. When you take into account their service life, [ergonomic] work bench systems aren’t really more expensive.” Once you include the various aspects mentioned above, it all adds up – barrier-free work bench design is well worthwhile. 

However, modifying an existing workplace to satisfy barrier-free principles is no easy task and involves a not-inconsiderable amount of work and expense. That is precisely why it is best to “go barrier-free” from the outset when designing new work benches. This approach paves the way for the future and taps into plenty of potential for experimentation. The “two-sense principle” is a good example for how far the concept of barrier-free working practices can go. 

Indeed, freedom from barriers is not just about obvious things like sitting, reaching distances and legroom – it’s also about sensory perception. It may sound obvious, but it is an aspect that is often overlooked. So what exactly is the “two-sense principle”? Well, it’s pretty simple – information on work safety, etc. should always be communicated in such a way that workers who are deprived of one sense can use another to access that information. For example, if an audible signal is being used as a warning, it should be backed up by a visual warning mechanism. All in all, it can be argued that decision-makers who opt for barrier-free work bench systems are also breaking down barriers that could otherwise stand in the way of their company’s future success.

Are you interested in ergonomics and freedom from barriers? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

From October 2017, seminar participants at the Hanover site can find out how to transform a conventional production system into a lean Industry 4.0 factory.

The motto of the learning factory in Hanover is “Experience LEAN live.” Factory Consultants, HeyDo Apps and item Industrietechnik have pooled their know-how in a seminar package to offer beginners and LEAN users an ideal learning environment. The transition from a conventional production system to a LEAN Industry 4.0 factory can be modelled step by step in an easily understood format in the learning factory. This involves introducing LEAN methods during various rounds of a planning game to reproduce the effects of measures in a practical way and apply them directly to participants’ own production operations.

During various rounds, participants learn about the key differences between conventional production and a Lean Industry 4.0 factory. To this end, the Factory Consultants GmbH training facility, which has a successful ten-year track record in teaching LEAN know-how, has been equipped with tablets to demonstrate the potential of paperless order processing and digital shopfloor management. The office workstations, storage facility and assembly line required for the planning game have been developed using the item Lean Profile Tube System D30  to enable particularly quick and easy reconfiguration. For example, the work benches can be redesigned over and over again during the seminar to ensure they best meet the needs of each round.

At the end of the seminar, participants are able to analyse a multi-stage process methodically, identify potential for improvement and use process and work bench design to significantly improve overall system performance. Unlike many other seminars, participants acquire practical user knowledge and apply this to real situations while they are still in the learning factory. An electric gear motor is used as an example product and comes in almost 300 variants made up of various components and assemblies to suit specific customer needs.

Realistic working environment as a real challenge

Round one simulates an everyday situation at a conventional company. Participants are confronted with typical production challenges – initiating an order without taking capacity into account, complex material and information flows, fluctuating work content and varying batch sizes. What is initially very easy in the module pre-assembly stage becomes a hopeless mess in places as problems stack up in the subsequent final assembly stage. Nothing seems ideal – neither the layout of the production line nor the workflow. 

From round two onwards, the problems are made visible by measuring key data and mapping the workflow, and participants are encouraged to improve the overall system. They don’t just use their own know-how to do this – true to the motto “how can such a company be optimised with our current range of experience” – but also use tools such as value stream mapping and methods such as 5S for work bench design. 

They are supported at all times by the seminar leader, who shows what adds value in the process and what process steps can be eliminated or optimised.

Planning games highlight increasing efficiency 

The comparisons after each round highlight how the improvements that have been introduced impact on planning figures. However, they also show where action still needs to be taken and what customer requirements have not yet been met. 

The better the participants get to know and understand the system, the better able they are to use LEAN to tailor production exactly to market needs. This includes introducing one-piece flow, Kanban, minimising setup times, simplifying material flow management and inventory sizing. The prerequisites for each method are clearly defined to ensure participants have the necessary knowledge to evaluate which methods are suitable for use in their companies. 

What makes the learning factory in Hanover so unique? 

As well as being taught lean methods, participants also find out how easy it is to create small and efficient cells with Profile Tube System D30. After just a brief induction, everyone is able to design work benches, repeatedly reconfigure them and improve details – all on their own and using just one single tool.

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

Opposites attract! Which is why a long-established Austrian forge has opted for our aluminium profiles.

They’ve been manufacturing high-quality forged parts in Köflach, Austria, for 300 years. Although it started life as a classic hand tool forge, Krenhof has continuously adapted to new technical and social developments. In the 1980s, as hand tools started to play an increasingly minor role in the economy, the forge adopted a new approach, becoming a specialist in metal forming technology and a supplier to the automotive industry. While in its early days the company had a workforce of 117 and processed 1000 metric tons of steel per year, today it employs 280 members of staff who produce some 27,000 metric tons annually. When it comes to in-house die making and a recruitment project for new staff, Krenhof has chosen to opt for solutions from item.

Ergonomic industrial work benches for die making

High-quality and efficiently organized die making systems are crucial for the success of a drop forge specialist such as Krenhof. Traditionally, the company had fitted out its workshops with typical work benches based on steel profile tubes, which involved significant outlay for the numerous processing steps from welding and grinding through to priming and painting. More importantly, all these steps had to be repeated each time a work bench needed to be modified. Naturally, the attractive appearance of the item solution also played a part. 

Besides being expensive, modifying the old-style work benches in-house also took up a lot of time. Both aspects had a detrimental impact on the flexibility that was expected from the company in its role as a supplier to global companies such as MAGNA, DOKA Schalungstechnik and MAN. All these reasons persuaded Krenhof to fit out its workshop with our flexible and ergonomic Work Bench System – a move that perfectly reflects its own motto: “A little bit better every day”. Since then, over a period of around five years, many of the former steel constructions have been replaced.

Encouraging young people to go into industry

Krenhof is not just using item components to ensure it can be flexible and efficient in how it responds to customer requirements. Like many other small and medium-sized enterprises, the drop forge specialist is also facing difficulties finding appropriately qualified and motivated apprentices for industrial roles. Krenhof also sees employee retention as a key element of its expertise in metal forming technology, the basis for which is rooted in ensuring the best possible apprenticeship training. 

In the ideal scenario, future apprentices would decide whilst at school which career they want to pursue and pick out a suitable company. The education system in Austria includes a special type of school that aims to meet that need – the “Polytechnic School” (PTS). Students start at a PTS once they have completed their lower secondary education and spend the remaining years of their compulsory education there, studying to take up an apprenticeship or start at a vocational college. Their studies include an extensive practical element, which is often delivered in cooperation with local companies.

Practical project – measurement bench from item 

The extensive practical elements of studies at a PTS include regular project days in the school’s own workshop facilities. One of these projects, which focused on “5S in the workplace”, was based around producing a custom-configured measurement bench. To give the students participating in this project a realistic impression of the state-of-the-art working processes at Krenhof, they were provided with components from the MB Building Kit System in collaboration with our Austrian partner Haberkorn. 

The impressive end result was built using mostly 160x40 profiles. More significant, however, is the fact that the measurement table was made a permanent fixture of the PTS workshop, so that future generations of students will be able to use it. The project also proved to be an out-and-out success for Krenhof, too. Three of the students who were involved have since decided to take up a training post at the company.

Are you interested in supporting young talent in industry? Then we have something that might just help! Simply subscribe to the item blog by completing the box at the top right!

What happens “behind the scenes” to ensure we can start the day refreshed?

Anyone who appreciates a comfortable sleep is surely familiar with pocket spring mattresses. They owe their success to their use of a large number of steel springs, each enclosed in its own fabric pocket. This provides a level of stability that is impossible to achieve in conventional sprung mattresses, significantly reducing the pressure on shoulders, hips and spine. What’s more, the number and resistance of the individual springs can be varied to create different comfort zones. In addition to innovative specialist machinery, our customer Macau Commercial has specialised in efficiently producing precisely this key component for pocket spring mattresses.

Production at record speed 

TaiWa Commercial was founded by Macau Spring Manufacturer and Macau TaiWa Machinery in 2011. Right from the outset, it focussed on all aspects of pocket spring mattress production. One incredible detail shows just how refined the company’s expertise has become – it now manufactures 140 springs a minute. In other words, it has achieved production speeds unrivalled by any of its competitors worldwide. Although the machinery was initially constructed using steel, the company switched to item aluminium profiles in 2015. 

“It is so easy to screw the profiles together – it’s much faster than welding, which is what we had to do with steel parts. It also gives us far more flexibility if we have to modify a construction. The aluminium profiles are much easier on the eye, too,” says Nelson Wu, the company’s director. Three different machines are used. The first winds the springs into their very special shape and sews them into their shaping pockets – all at incredible speed. The second machine cuts the long strips of springs to size, before the pockets are joined together in the third and final step. Around 95 percent of the structures in the factory now consist of solutions from item, with the wide range of profile technology in the MB Building Kit System playing a vital role. It is perfect for the various areas of application. 

Flexible and environmentally friendly 

It is easy to swap out individual components and reuse profiles in other places. This fits in perfectly with the efforts of the Chinese government to encourage companies to take more account of environmental factors. According to Nelson Wu, using our aluminium profiles has as much to do with careful observation of western markets as it does with industry developments in Asia. “We are guided by global competition – especially what is happening in Europe and the United States – so we know that item’s profiles are often used there. At the same time, there is a new trend in specialist mechanical engineering toward using aluminium profiles to build machinery. There is therefore a lot to be said for using item.”

Do you want to keep up to date about global news from item? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

How two key performance features of cutting-edge industrial work benches complement each other perfectly thanks to compatible interfaces.

Even in times of innovative solutions for automating working processes, manual assembly remains one of the main keys to efficient production flows in many industries. Ergonomics and intralogistics at industrial work benches are essential factors in achieving this. They lay the foundations that allow each employee to use their full potential to achieve consistently high production quality with low throughput times. In this article, we make it clear once again why a cutting-edge work bench system only achieves its full potential in terms of boosting manual production efficiency when the individual elements fall into place.

Why ergonomics is so valuable at industrial work benches

Many companies still underrate the importance of ergonomics in industrial production. It is easy to overlook the clear benefits of ergonomic design in industrial work benches, as they only become clear on closer inspection. Ultimately, ergonomics is not primarily about more comfortable working conditions, but rather maintaining the high productivity of manual assembly staff for the long term.

An electrically height adjustable work bench, for example, enables employees to switch easily between sitting and standing while carrying out assembly work. Since different people are different heights, employees can select the bench height that suits them best. Without this kind of option, smaller or particularly tall workers are forced to adopt an uncomfortable posture before they even start their work. The same applies to material supply and picking, which can help boost production efficiency when it is not static but rather can be adapted to the specific handling area of each employee.

Using intralogistics to achieve fast throughput times

The full potential of ergonomics at industrial work benches can only be harnessed when not hindered by delays in other areas. A critical point in this is often material resupply for the worker at the bench. There is a good reason why the efficient management of resupply systems is a major factor in lean production. The FIFO process and just-in-sequence are just two examples of practical solution.

When it comes down to it, the aim of efficient intralogistics is always to ensure the production work of manual assembly workers is disturbed as little as possible. If workers have to interrupt their work when new material arrives, or worse, have to go and get the material themselves from a central pallet, this represents an unnecessary waste of time. The main aim in intralogistics is to ensure work benches are supplied with standard containers that are as large as possible, with no need to worry about sorting. The perfect intralogistics system thus both safeguards the flow of materials and uses grab containers and grab plate profiles to create a direct interface with individual industrial work benches.

Ergonomics and intralogistics become ergologistic^®

This interface is precisely what item ergologistic^® is all about. Industrial work benches designed using this principle combine the benefits of ergonomic work bench design with continuous material resupply, allowing workers to concentrate fully on value creation. For example, with item ergologistic^®, small parts in standard containers can be resupplied to industrial work benches simply by sliding them in from the rear on trays fitted with a raised edge at the operator’s side. The transport trolleys are constructed from the same modular components as the work benches so that both elements can easily be adjusted to each other to provide smooth transfers.

In summary, production processes can only be made significantly more efficient by seamlessly combining ergonomically optimised manual production steps with the time savings that come from perfectly connected intralogistics. The fact this holistic ergonomic concept also significantly reduces the risk of long-term musculoskeletal disorders is an added bonus to the already positive effect of these systems.

Do you want to keep up to date about innovative solutions from item? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

How the first sophisticated steam engine in Germany safeguarded the mining of copper shale under extreme conditions in one of the most important mining regions. 

In an earlier article, we looked at the question of what “automation” means. During our journey through time, we have come across important figures like Heron of Alexandria and explored the effects of the stream engine. After all, breaking free from dependence on the physical power of animals and humans was equivalent to a revolution. All the same, it is easy to overlook the fact that the steam engine was originally deployed in a completely different context – the mining industry. It is in that same context that the steam engine was first put to use in Germany. 

The answer to a pressing problem 

On 23 August 1785, the first German steam engine – built to the design developed by James Watt (1736-1819) – went into operation at the König-Friedrich pit near Hettstedt in what is today Saxony-Anhalt. Copper shale was originally to have been mined there in 1782, but the flow of water into the 100-meter-deep shaft was far too strong. Without a new form of technical assistance, it would have been impossible to pump out enough water to allow mining work to go ahead uninterrupted. The conventional method, which relied on a horse-drawn pumping station, was simply unable to cope with the high flow rate. 

It was an unescapable problem, particularly since the area had been mined since the Reformation and all deposits near the surface had already been excavated. There was now only one way to go – down. The commission responsible quickly realised that a state-of-the-art steam engine was required, so they got in touch with up-and-coming engineer Carl Friedrich Bückling (1756-1812). After being presented with a 1:6 scale model and a persuasive cost estimate, the Prussian king finally approved Bückling’s plans. 

The first German steam engine – genesis and legacy 

Some components for the ambitious project were produced in a purpose-built plant, while others were manufactured at various companies spread across the whole of Prussia. Meanwhile, work got under way on extracting copper shale, albeit with temporary support from horse-drawn pumping stations. After some teething problems, Bückling’s steam engine put in a sterling performance and was further improved on a number of occasions. By 1794, it was time for a new model, also engineered by Bückling. Although the new version proved a success and remained in use for twenty years, it is its predecessor that has stayed in the region’s collective memory. The original was not consigned to scrap either, it was moved elsewhere, to Löbejün, where it continued to work until 1848.  

To this day, the region is very proud of Bückling’s steam engine. A working model (a reproduction) of the original machine is on display at the Mansfeld-Museum in the Humboldt-Schloss in Hettstedt. In 1885, the Association of German Engineers (VDI) even set up the “Maschinendenkmal” (Machine Monument) at the slag heap of the König-Friedrich pit. A plaque on the monument contains the following text: “On 23 August 1785, on this site, the König-Friedrich pit, the first steam engine built by German workers using German materials went into long-term commercial use.” The monument was smartened up in 1985 and 2015 on the occasion of its 100 and 130-year anniversaries. Any way you look at it, a trip to Hettstedt is well worthwhile for any enthusiastic engineer.  

Are you interested in fascinating stories and personalities from the history of engineering? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

Putting profile technology for lean production into a different, but no less exciting, context. 

The aesthetics and style that surround us always have a big part to play in our home life and in creative working. In other words, atmosphere is key to lifestyle and quality of life. We, of course, are fully aware of this, and understand that our Profile Tube System D30 is both functional and pleasing to the eye. At the same time, item stands for mechanical and factory equipment engineering products that can also be used in other settings. The idea of using furniture from item at home or in the office may seem surprising at first. However, the combination of stylish industrial aesthetics and efficient fasteners is so attractive that it just has to be put to use. The same thought occurred to some of our creative colleagues, and they promptly sharpened their pencils and got to work.  

A connection that creates elegance 

An earlier attempt had been abandoned when it hit a major obstacle – the lack of an internal fastener. This is a much smaller version of the standard fastener that uses plug-in technology to hold the individual tubes together. Fundamentally, the internal fastener has the same diameter as the tube it connects. This creates smooth transitions, and above all ensures a flowing, elegant aesthetic. With that final obstacle now overcome, we set out on our journey into the exciting world of interior design. 

Some D30 shelving units have already been produced, and these now grace a room in our company headquarters in Solingen. As the illustrations here show, a lot more is still possible, such as tables and the sideboards in the background. For now, they are still only “virtual” designs, but there is nothing to stop them being built. In our “lean furniture” concept, we are specifically aiming to provide all-in-one solutions with no unnecessary frills that combine functionality with elegance. We would be very happy to help anyone who is looking for furniture for loft-style living or office contexts.   

We value your opinion 

In this setting, one factor has to be considered that is unimportant in industrial applications – no-one wants to have to put together complicated structures on their own. We can reassure you right now that customers don’t have to worry about anything. We mill the panels ourselves or have materials such as solid wood and high-quality veneers processed by a carpenter. The panels we use have a curvature that simply drops over the curve of the profile tube. Cupboard doors, shelves and table tops are all easy to create. 

We simply wanted to see what would happen if Profile Tube System D30 was used in a home or office setting. What do you think? We welcome your feedback! Feel free to contact Stefan Mostert (s.mostert(at)item24.com).  

Want to keep up to date with all the exciting innovations from the world of item? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

It really gets under your skin – thousands of single-use needles are required in doctors’ surgeries and clinics every day.

Whether they are used for blood tests or injections, no other object is as closely associated with medicine technology as the syringe. As is often the case in the life sciences industry, producing single-use needles and syringes means that two very different concerns have to be taken into account – zero tolerance of hygiene issues and cost-effective production. The Dresden-based company Konstruktion Maschinenbau Vorrichtungstechnik (KMV) Müller has designed and built a sophisticated pick-and-place machine for a pharmaceutical industry customer that meets precisely these requirements. 

GMP with Line X from item

For item pluspartner KMV Müller, the major challenge in designing the machine lay in the demands placed on machinery used in the pharmaceutical industry. Top priorities in this field include minimising any potential for machines to get dirty or contaminated, and ensuring easy cleaning for the entire system. Machinery manufacturers must comply with Good Manufacturing Practice (GMP) guidelines, which regulate all processing stages. The tried-and-tested Line X profiles from item proved to be perfect for this application.

Pick-and-place systems are automated workpiece positioning systems. They can be used to select a required part from a large number of other workpieces. The part is then transferred to a defined position for further processing. The KMV Müller machine is used to individually select single-use needles to be attached to syringes in medical surgeries. The sterilised, approx. 60 mm long needles are fed into the machine as bulk material. 

Precision and speed

The pick-and-place machine is therefore fitted with a "stock bunker". With the help of a conveyor belt, the needles are transported into a centrifugal feeder and positioned precisely. A linear conveyor then transfers the sorted syringe pieces to the release system. Here, two grippers ensure that the individual workpieces are positioned within the release system cleanly, and that they do not get so close to each other that the dynamic pressure causes them to tilt as they are transferred to the next stage. 

Next, a robot equipped with vacuum cups extracts the single-use needles from the release system and places them into a sequencing chain. The machine is fitted with its own operating console for individual programming. The signal tower uses different lights to give operators a quick and clear overview of any faults (red), material bottlenecks set to arise within 15 minutes (blue), or problems with a pre-process machine (yellow).

Life sciences engineering with item

Operating at a rate of 100 units per minute, this is an exceptionally efficient yet still remarkably quiet machine. Thanks to the use of an enclosure made with item polycarbonate panels and a conscious decision to use low-noise feed and transport components, it complies with the recommended occupational health and safety noise level of 70 dB. Since KMV Müller first installed and commissioned the machine, it has run without any faults and is regularly maintained by the pharmaceutical company’s technicians.

This article first appeared on the item pluspartner blog. Do you want to keep up-to-date with how item is bringing lean production to the life sciences industry ? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

More than 100 hours of work, 14,000 individual parts, a length of 1413.67 metres, and lots of item products – the perfect conditions for a world record.

Klaus Peter Beier is a man with a passion for world records. Hailing from Alpen in the Lower Rhine region of Germany, he has already collected 15 in his career – for everything from the largest paper boat to the longest domino run of CD cases. In many instances, these records required physical effort – like when he completed 100 rounds on Europe’s highest wooden roller-coaster. For the marble run record he set in Bremen in 2014, on the other hand, he needed a lot of patience, a steady hand for precisely positioning the numerous components, and a suitable framework from item.

Why process optimisation under cleanroom conditions places stringent demands on the planning and selection of suitable components.

Maquet is a leading manufacturer of medical systems. Established in 1838, the company’s products are primarily used in the critical areas of hospitals such as operating rooms, intensive care units and laboratory environments. As a result, the products – and therefore the associated production environments – have to meet high quality standards. At the same time, competition in the medical technology sector is getting ever tougher, meaning that success is not just dependent on delivering optimum quality, but also on achieving the best possible production efficiency based on lean production. To test out how production processes in cleanrooms could be optimised, the company decided to refit a pre-existing manual assembly system for a compact centrifugal pump used in portable heart lung machines.

Working ergonomics in manual assembly

The centrifugal pumps are manufactured in line with stringent ISO 13485 and GMP hygiene and cleanliness requirements in a specialised site that Maquet runs in three-shift operation. However, another site took over many of the workstations that had been used there to date. As a result, the individual stations were not standardised, nor were they modular, which meant there was not enough flexibility to implement the planned improvements. The decision was therefore taken to establish a new production line based on the lean philosophy.

This process optimisation centred on switching to a U-line with short routes between the individual assembly steps and one element of this involved improving workplace ergonomics. To achieve this, the individual working areas would need to offer flexible adjustment options to ensure workers of very different sizes can always lay their hands on tools and materials in their personal handling area with the greatest of ease. Since sensitive electronic components are installed during the production process, end-to-end ESD protection was also an essential requirement.

Optimising processes in the cleanroom with item

After completing its internal planning for the production line refit, Maquet turned to item for the practical side of things. There were three main reasons for this. Firstly, the in-house workshop at the site had already been working with our versatile aluminium profile technology for quite some time, and with great success. Secondly, Line X offered an ideal solution as a profile variant without grooves that is easy to clean, resistant to the cleaning agents typically used in cleanrooms and electrostatically dissipative, making it ESD-safe.

Thirdly, and no less importantly, the high availability of item components and our delivery reliability also proved crucial to this project. Converting the production system to a U-line during three-shift operation and under cleanroom conditions simply was not an option. All that was left was a very tight timeframe over the Christmas holidays when production stopped. Delivery delays or the unavailability of components would almost automatically result in the project being put back at least six months.

Lean strategy from bottom to top

It was also important to Maquet, as the basis for its in-house lean strategy, that employees be involved as much as possible in developing the manual assembly work benches. Staff who work in an area for eight hours a day usually have a good feel for potential improvements. If these can be realised simply using flexible material supply systems, modular components and electrically height-adjustable work benches, not only will that improve production efficiency, it will also motivate employees and make them more likely to embrace the new production environment.

By pursuing this strategy with reliable partners, Maquet succeeded in boosting productivity on the production line by 20 percent. Putting the various measures into action as a team helped the company cut throughput time by 10 percent and rejects by 8 percent. 

Do you want to keep up-to-date on how item is making lean production possible in cleanrooms? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

How an unusual racer based on item profile technology is helping families in need get back on track.

Located in the U.S. State of Georgia, to the north-east of the capital Atlanta, Lawrenceville is normally a quiet place, but that all changes during the annual Bed Race – a local event in which numerous companies and individuals from throughout the region participate. In 2017, as in every other year, our customer WIKA Alexander Wiegand SE & Co. KG took part with its very own “bed racer”. Headquartered in the German town of Klingenberg am Main, the specialist in pressure, temperature, flow, level and force measuring technology is represented in over 40 countries with more than 9,000 employees, including the team from Lawrenceville. With high quality standards and a focus on lean production, WIKA has long been using solutions from item, so it was an obvious choice also to use the flexible components from the MB Building Kit System to build the racer.

Specific bed racer requirements 

Although the Family Promise of Gwinnett County (FPGC) Charity Bed Race is naturally not on a par with a race series like Formula Student, specific rules still apply to building the bed racers. The compulsory mattress dictates the width, while the structure’s total height must not exceed 243 cm. Protruding parts, such as the handles for the four pushers, must not have any sharp edges or stick out by more than 40 cm. 

What’s more, the handles must be arranged to ensure all the pushers have a clear view of the course at all times. They are the only form of propulsion during the race – no pedals are allowed, and certainly no motors or engines. The team member sitting on the bed racer, who must weigh at least 45 kg, doesn’t really have time to relax. This person must use a steering mechanism to keep the minimum of four wheels within the specified lane and negotiate two bends on the course measuring just under 258 m.

Fully committed to the 2017 bed race

On paper, this is without doubt a task the team from WIKA can solve. After all, the company’s products cover measuring ranges up to 15,000 bar and 1,800°C in batch sizes extending from 1 all the way up to 10,000 units. An estimated 600 million or so measuring instruments from WIKA are currently in use worldwide. It was therefore no great surprise when an impressive bed racer lined up at the start on race day in April. Line 8 profiles reinforced with Angle Elements at key points formed the lightweight frame. The problem of sharp edges was solved using Caps and a number of clearly visible advertising spaces also fitted into the profile grooves along with measuring technology from WIKA.

This was the basic configuration for the races, each of which involved a direct duel with another team competing in the event. The pushers needed a high level of fitness, because the times posted were only valid if all team members were still in direct contact with their own bed racer on crossing the finishing line. Ultimately, WIKA left teams with names such as Cool Runnings, Pigs in a Blanket and the Flying Nuns trailing in its wake. ViaSat was the only team in the adult division to get the better of it. The real winners of what was Lawrenceville’s eighth Bed Race were totally different, though.

Social responsibility part of the corporate culture

There’s a serious side to the Bed Race, too. In the United States, as in many other countries, numerous families are living on the breadline despite being in work. Rents are often the biggest cost factor for these families and, in the event of unforeseen problems or strokes of fate, it’s their homes they lose. This then often also leaves their children homeless. Some of those affected are unable to recover from a setback of this kind without help. The volunteers from Family Promise use initiatives such as the Bed Race to raise awareness of this very problem, because everyone should have a bed in a safe environment to sleep in. 

The annual race has now become one of the region’s biggest charity events, with local companies like WIKA demonstrating an impressive level of social responsibility. The proceeds aren’t only used to organise accommodation for families in need. They are also given training in applying for jobs, can look for new jobs online and, if necessary, have access to free transport. It goes without saying that the families themselves are also expected to demonstrate their commitment. As long as they do, they can benefit from direct support for up to 90 days. Even after this period, Family Promise is on hand to offer help and advice.

Want to keep up to date with everything that’s going on in the world of item? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

How material supply and picking for coolant pump assembly is benefiting from low-cost automation. 

We have already dealt with the history and basic principles of Karakuri Kaizen in another post. It is a form of automation that is based solely on mechanical energy and thus requires no support (for example from drives of any kind). Now we turn to the practical side of things – using the example of an item solution developed for NIDEC GPM GmbH. Based in Merbelsrod in the Thuringia region of Germany, the company is one of the leading manufacturers of water, oil and transmission fluid pumps. NIDEC GPM’s customers include many renowned car manufacturers such as VW, Daimler and Jaguar.

Lean production with item 

The primary aim of this measure was to ease the load on the company’s logisticians, who had previously had to lift goods uncomfortably in and out of racks during material supply and picking operations. Whenever a tray was empty, they immediately had to re-stock, or – if the logisticians were occupied elsewhere – the operators had to stop what they were doing and take care of that themselves. This is where a customised Karakuri solution for low-cost automation from item comes in – and it even goes around corners. 

The logistician uses a pulley to move the workpiece carriers into one of the three lanes in the special rack construction. Thanks to the sloping design and roller conveyor, everything stays in motion. The workpiece carriers containing the individual parts for the coolant pumps are transported without any additional outside influence straight to the operators, who can later forward them on to the assembly line for the coolant pumps. 

The Karakuri rack is an improvement for the operators, too, as they receive the parts they require at an ergonomic height. The Karakuri solution also enables them to work autonomously for several hours. “They can now work on the piece for four or five hours before the logistician has to re-stock them,” says Tobias Kieser, head of work scheduling. This is important because the assembly system is fully automatic, and therefore has to be constantly fed by the operator, who gathers the empty trays afterwards, sending them back via the return system so that the logistician can pick them up. This takes material supply and picking to the highest level of efficiency. Optimising processes while also lightening the load is one of the core tenets of the Karakuri mindset. 

Karakuri = lean and ergonomic 

As a subsidiary of the Japanese NIDEC Corporation, the lean philosophy is already firmly established in the central principles of the company. Tobias Kieser is committed to this approach: “We are always working to apply the lean philosophy in new areas and develop ourselves, in line with the principle of continuous improvement.” What’s more, efficiency is a top priority in the automotive sector. 

Employee welfare is equally important at NIDEC GPM, however, which means ergonomic principles are also taken into account. Efficiency and an ergonomic approach complement each other perfectly in lean production. In this regard, Karakuri in particular is perfect for this corporate profile and the associated requirements, as Kieser says, “Karakuri accommodates ergonomics very well.” 

Trusting collaboration 

Even before the start of the Karakuri project, NIDEC GPM GmbH was already very familiar with our profile technology, having used it in existing systems and machinery. It became aware of this item product segment during a lean production training course, when the trainer presented two of our lean solutions. Kieser then contacted our sales department, and soon after that the two partners started to look into the issue together. 

The fruitful discussion that followed resulted in the supply solution described above. Kieser has nothing but praise for how the project was run and the effectiveness of the Karakuri rack: “Everything has worked incredibly well and without a hitch.” As a result, a follow-up project is already under way. Once again, the aim is to ensure operators receive parts at the ergonomically correct height and with very little effort. Things are a bit more complicated this time, however, as the Karakuri solution has to navigate several corners. 

Do you want to keep up to date about innovative solutions from item? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

The relaunched item website is just as flexible and modular as our building kit systems for industrial applications. 

Access to product information, content and downloads is now easier than ever for existing and potential customers. The new high-end design catches the eye immediately, stretching the full width of the screen. This makes the most efficient use of the space available, whether item24.de is being accessed from a desktop, tablet or smartphone. The fonts, colours and all clickable buttons have also been freshened up to ensure the website displays in the same high quality on every end device. The new design also supports the use of large-format images and videos, highlighting even better the bounty of innovative details that characterise solutions from item.

A direct line to service at any time

Another detail of the new item website that jumps out immediately is the contact flyout. The red menu on the right-hand side of the desktop view means visitors are only ever a click away from our skilled online service team, no matter what page they are on. During business hours, they can choose to either chat direct to a customer service advisor or, thanks to a cobrowsing function, have support accompany them as they look through the pages of item24.de. 

Alternatively, and outside business hours, the letter icon provides a new way of looking for a contact. By entering a German postal code or selecting another country, existing and potential customers can see at a glance where and how they can reach their nearest customer advisor. The flyout also enables customers to access their current shopping basket at any time.

Completely new look – the item Online Shop

The best example of how the entire website is now more user-friendly is the item shop, which can now be used just as easily on any end device. A flyout can be opened using the main navigation menu at the top of the website pages. This menu only appears when required and provides an initial overview of item's entire product range. As soon as a product group is selected, a short introductory text appears to the right of this explaining the key areas of application and benefits. This is particularly useful for potential customers who are not yet familiar with all of the item product groups.

Another major help on the way to finding the perfect solution is the search function, which is also new and more efficient. The results of each search are divided into clusters according to type, enabling customers to sort them by products in the shop, topics and content on item24.de, and technical documentation and product catalogues in the Download Centre. Thanks to its focused, design-based navigation and stripped-back appearance with no confusing overloaded areas, the new website is a digital customer advisor in its own right.

Download Centre and online tools

To help existing and potential customers access advice and support as efficiently as possible, the website is packed with opportunities to jump to key application areas for item profile technology. These tabs lead directly to lean production and other popular product areas. Other areas of the website feature filters that can be used to narrow down the wide range of information available on item24.de and focus on specific requirements and interests. For example, the content of the Download Centre can be filtered by category. Besides downloading content directly, users can also add relevant catalogues and documents to a watch list. The content of this watch list can then be downloaded collectively with a single click.

It goes without saying that we would like all our customers to have access to these benefits, so we will gradually be adapting the websites of our item partners outside Germany and our numerous additional offerings to the new, cutting-edge design. In the medium term, item will have a uniform web presence. The usability advantages are already clear in the item Machining Tool – especially on tablets and smartphones. The freshly revised Lean Glossary is also worth a look.

Want to keep up to date with what’s going on in the world of item in future? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

The latest new products from item make it even easier to achieve innovative Karakuri solutions, new applications for safe factory equipment engineering and optimum work bench lighting.

Pivot Bearing Set D30-28.5 M8, Roller Set 8 D30-30 and Tool Balancers with synthetic fibre cables are three products that boost efficiency in the design of mechanical automation solutions. The new Spotlights 6W LED, meanwhile, light up the dark, helping users by providing the optimum lighting for work benches and integrating seamlessly into the existing lighting range from item. Further additions to the components in the item Hook and Holder System make it easier to keep the work bench well organised. And when it comes to moving pallets, trolleys and containers with forklifts and working at mobile work benches or racks, the new Forklift Pocket 8 St 260x90x40 and Jacking Castor D80 provide perfect support. 

Precision movement of light loads

Our new components for low-cost automation applications offer added flexibility for implementing Karakuri solutions. Heavy small load carriers (SLCs) are usually ideal for purely mechanical automation systems, as they initiate the associated processes by virtue of their weight alone. A combination of Pivot Bearing Set D30-28.5 M8, Roller Set 8 D30-30 and three different Tool Balancers with synthetic fibre cables offers an especially lean solution. Users benefit most from using these robust products in low-maintenance transport applications for light SLCs. For example, the new components can be integrated into low-cost automation applications to help boost ergonomics at industrial work benches.

The compact Pivot Bearing Set D30-28.5 M8 can be inserted very easily into the standard Fastener D30. Thanks to the exceptionally easy-running and low-friction bearing, the construction kit is ideally suited for use in hatch designs. Karakuri solutions like these involve placing the workpiece carrier or SLC on the hatch, causing it to fold down and transport the carrier/SLC via an incline. Double Pivot Bearing Unit D30-28.5 M8  enables rotary motions with profiles that are only secured at one end, i.e. when seeking to move light parts in a tight space.

The all-important advantage to Roller Set 8 D30-30 is that there is no need to incorporate an additional guide profile in the frame for moving components such as carriages, cables or counterweights. The double ball-bearing rollers run very smoothly with low wear. Designs are rounded off to perfection with the new Tool Balancers that feature highly flexible synthetic fibre cables. Unlike steel cables, these synthetic counterparts can be routed around even small rollers without wear or splaying.

Perfectly lit work benches

Perfectly prepared for use in harsh industrial environments – that is the key feature of the new Spotlights 6W LED. Cutting-edge LED technology, illuminance of 20,000 Lux and an optimum colour temperature of 4000 Kelvin create the best possible lighting conditions for focused, efficient working practices. Due to their compact shape and the IP65 protection their casings offer against dust and water ingress, they are ideal for use in tight machine cabins. With a service life of more than 50,000 operating hours, they are exceptionally low maintenance. Spotlights 6W LED are available with lighting angles of 10 and 35 degrees. This ensures the working area can be lit up at specific points or over a wider area, as required. 

The additions to the item Hook and Holder System make it even easier to efficiently organise tools and equipment directly at the work bench. While Container Holder 8 holds inherently stable containers securely in place, Single Hooks 8 40x20 and 80x20 and Double Hook 8 80x20 are ideal for hanging up tools and clothing. The loops of stainless steel wire are each bent up at the end to stop articles slipping off and to minimise the risk of injury. 

Order and safety for intralogistics 

The latest additions to the MB Building Kit System are all about maximum safety and full process control in intralogistics. For example, item has developed Forklift Pocket 8 St 260x90x40. This acts, on the one hand, as a guide rail for the forks of floor conveyors when moving trolleys and containers safely. On the other hand, because it is fitted to the underside of the profile frame on a load carrier, it also stops forks damaging the frame. Since Forklift Pocket 8 St 260x90x40 fully envelops the forks, it also effectively stops the load from slipping or tipping when being carried over uneven floor surfaces.

The new Jacking Castors D80 with Foot Pedal for mobile work benches or racks bring added stability to intralogistics applications. They combine a height-adjustable castor with a non-slip knuckle foot to ensure a secure hold while work is being carried out. A foot pedal allows staff to lower the castor without having to bend uncomfortably. A simple foot-operated action also raises the work bench or rack again so it can be moved to the next location.

Want to keep up to date with everything that’s going on in the world of item? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

The Campus Motorsport team is starting this year’s Formula Student race season with a brand new pit and tool trolley.

item has had dealings with this competition before, having previously provided the team from RWTH Aachen University with a perfect exhibition stand. This new challenge, however, was much closer to the real action and required a practical solution that the team from Hanover University of Applied Sciences and Arts could use at the weekend race meetings. The Campus Motorsport team under the technical direction of Roman Stöcker had previously been forced to use a modified generic trolley to transport its equipment. Although it was big enough for all the various materials and the driver’s gear, it lacked flexibility and couldn’t be divided up into smaller sections to allow rapid access. What’s more, the toolbox was only connected to the trolley by a makeshift arrangement.

High-profile racing

Anyone familiar with our MB Building Kit System will know this challenge was right up our street and the item team was literally in pole position when Campus Motorsport approached us with its fully developed concept, including dimensions and requirements. The task of developing this concept had been given to the two newest members of the 27-strong race team for the 2017 season as their first job. 

During a visit to item, the students were able to witness the flexibility of our profile technology as our design engineers finalised the design ready for production and cut the aluminium profiles to size. The students themselves then completed the quick and easy assembly of their new item pit and tool trolley.

item pit and tool trolley  

The impressive result will open up new opportunities for Campus Motorsport. The item pit and tool trolley provides easy access to tools, helmets, spare wheels and replacement parts, while locked compartments offer secure storage for valuables and documents. In short, the team can now quickly relocate its pit area and keep everything it needs in easy reach close to the vehicle.

Naturally, there’s much more to come, though. Thanks to its modular design, the pit and tool trolley is easy to extend, and there are already medium-term plans for further additions – including a laptop holder, a parasol holder and possibly its very own music system. The end result would be very similar to the professional conditions in the big-name racing teams. It also reflects the Formula Student teams’ commitment to the competition.

Getting into motor racing

Campus Motorsport Hannover was founded in 2007 as FHH-Motorsport at Hanover University of Applied Sciences and Arts and has been competing in Formula Student since 2009. The wide range of disciplines offered by the university is a big advantage. There are around 10,000 students on a total of 60 accredited degree programmes in five different faculties – not only engineering and economics, but also numerous media and creative courses. The Campus Motorsport team includes students from virtually all disciplines. Their shared goal is to design a formula racing car. 

The mechanical engineering, business management, electrical engineering, information technology, information systems, design and journalism students assign tasks within the team in the same way as a professional racing team. From project management to component integration, everyone works towards a common goal and can contribute and improve their own know-how. The synergy effects resulting from this deliberate interdisciplinary approach enable the team and its members to make good progress. 

Career launch pad

The project management team controls and manages all team processes, which makes it a key success factor. Such a big project can’t work without centralised planning and a clear division of tasks. Especially when it comes to finding sponsors, it’s vital to identify requirements and get talking to appropriate companies earmarked as potential sponsors and development partners at an early stage. Ensuring everything runs smoothly and creating a professional image are key factors here and it’s up to the project management team to set an example.

The level of commitment required in the Campus Motorsport team does more than just prepare students for their subsequent working lives. For some team members, it also represents their first step towards higher racing classes and, ultimately, a career in professional motorsport. That doesn’t make the race events in which Campus Motorsport is involved any less important. Even at this level, 15 to 20 team members are required at the circuit to get the most out of the racing car. 

Petrolheads

Campus Motorsport always selects team members as drivers – but no-one starts off as a driver. Everyone who has made an outstanding contribution to the team and demonstrated an appropriate level of commitment is given the chance to take the car out on the circuit. The most talented drivers move on to the next stage and are prepared for racing with intensive training. You don’t have to be a licensed racing driver to compete in Formula Student, though.

During the current season, the Campus Motorsport drivers will compete against the other teams in a completely restyled Pegasus 17. Combined with colour accents from the corporate design, the car’s streamlining and newly developed aerodynamics make it a real eye-catcher. This summer, the Pegasus 17 will be speeding round circuits at locations such as Varano de’ Melegari in Italy, Most in the Czech Republic and Györ in Hungary.

Want to keep up to date with everything that’s going on in the world of item? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

How companies with real-time localisation and localisation-based order management can benefit from new lean production methods.

Along with Industry 4.0, a common theme on the item Blog is the 7 Muda and other approaches to lean production. With margins tight and competition stiff, production efficiency is a big issue for many small and medium-sized enterprises (SMEs). And although plenty of companies understand how to use the continuous improvement process (CIP) to achieve lean production, the problem is knowing where to start. 

One challenge in lean factory design concerns the time delay in getting access to crucial data. Problems can, of course, usually be retrospectively traced back to a particular production order and the workforce can be relied on to suggest potential improvements. All the same, to achieve optimum production management, production planners need access to information in real time.

CIP based on real-time localisation

To rectify this situation, Ubisense has developed a custom configurable management system that can be used to optimise production processes and reduce errors in the manufacturing process – and do so without interrupting production. At the heart of the “Ubisense Smart Factory” is real-time localisation based on a high-precision indoor GPS. This system identifies the position of objects in production and tracks their movement – all with an accuracy down to 15 cm. This method eliminates the time-consuming process of label scanning and thus reduces reaction times and production costs.

A whole host of customers, including Airbus and BMW, are already using the Ubisense Smart Factory. However, the system is not just suitable for large companies. SMEs in particular can benefit from real-time localisation and management systems.

Localisation-based order management reduces management outlay

Lean factory design is an interesting concept for companies of all sizes, since investment costs are largely directly proportional to the size of the in-house production operations. All it takes to implement the Ubisense Smart Factory is an incredibly simple infrastructure comprising small and active transponders (tags), sensors and the user software. Once all the orders in the production system have been given a tag, sensors in the building capture signals from the tags and calculate their position several times each second.

At the same time, localisation data from production is sent in real time to the user software and processed. The progress of customer orders is mapped in the software, which generates a whole new level of transparency. Localisation-based order management ensures that order progress can be accurately tracked at all times, as can the development of bottlenecks and weak points in production. Production planners are in a position to respond immediately and thus continuously improve production processes.

Production planning based on “lean factory design”

One aspect to this optimisation process is the reduced management outlay involved in fine-tuning transitional periods within the software. With Lean Factory Design, users can develop a process-optimised layout for their in-house production. A key requirement for localisation-based order management is that this layout can then be transferred to the management system.

Without interrupting production, Ubisense real-time localisation is used to assign customer orders to all the process steps in this layout. The localisation system captures the coordinates of each individual order in real time and identifies when an order has entered and left a process step. Subsequent orders are then automatically released. The advantage of this system is that response times are further reduced and customer order tracking is made a top priority. Production operations that organise and optimise themselves ensure that the best possible use is made of resources. This smart factory approach can give companies a considerable advantage over the competition.

Want to keep up to date with progressive production and production planning methods? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

The lean philosophy can do more than just boost efficiency in production.

We’ve already looked in detail at the principles of lean production, including issues such as 7 Muda, 5S, Just in Sequence and FIFO. Initially, we deliberately avoided an area that is increasingly coming into the spotlight – lean management. This is only right, because the fundamental thinking behind the lean method can also be applied to a company as a whole – with a few tweaks. However, there is some confusion about the terminology here – where does lean management end and lean production begin? Or should that be the other way around? 

From lean production to lean management 

The popularity of Toyota Production System (TPS) around the world is rightly seen as a success story. James Womack, Daniel Jones and Daniel Roos analysed the methods of the Japanese automobile industry and won them greater recognition through their book “The Machine that changed the World: The Story of Lean Production”. Since then, the successful principles of what has become known as the lean production method – avoiding waste, continuous improvement, valuing individual employees – have become standard in industrial production. 

Once lean production had taken hold, it quickly became clear that these principles could also be used to optimise processes that are not directly linked to industrial production. This led to the wide-ranging discipline of lean management. After all, the drive to optimise processes by avoiding waste and continuously improve applies across the board. For lean management to be taken seriously, its principles must guide the entire company. The concrete aim is to improve efficiency while also cutting costs and tightening the focus on customers. In this sense, lean management can be seen as a corporate philosophy for all levels to live by, while lean production applies to the production halls in particular. 

Lean management principles 

Systematic lean management basically hinges on three principles: 

1.) Continuous improvement 

What is true for lean production is just as important for lean management – the continuous improvement process (CIP) defines everyday work processes. It has been adapted from the traditional Japanese attitude of “Kaizen” (Kai meaning “change”, and Zen “for the better”). 

When applied to work and management processes, this has the following effects: It establishes a fault culture that is very different from the conventional approach. Errors are seen as a starting point for improvement rather than a mark of shame. The CIP never ends, since every process can always be further improved, and all that is required is a more detailed analysis. This should never be seen as a negative thing – quite the opposite. There is always potential to do better. 

2.) Process orientation 

The second pillar of lean management is process orientation. This means moving away from a department-based mindset – or silo mentality – and focussing instead on the actual process as a whole. This change in thinking can also be seen as a move from favouring specialist expertise to promoting interdisciplinary working. Taking a detailed look at processes also makes it easier to implement the CIP. 

3.) Customer and staff orientation

Another key factor is focussed customer orientation – although no distinction is made here between internal and external customers. The same care needs to be taken whether making a delivery to staff in another department or processing an order for a new external customer. Levelling out rigid hierarchical structures also enables employees to become more involved. 

Lean leadership 

Flatter hierarchies, greater efficiency and an awareness of avoidable waste can quickly lead to tangible effects and act as a launch pad for lean management. The concept of lean leadership is also very useful as an ideal. This places greater focus on enabling staff, and displays remarkable overlaps with the progressive ideas of Henry L. Gantt. The entire company benefits when managers systematically work on improving their own skills and those of their team members. In the ideal case, this is the purest form of implementing the continuous improvement process. 

Want to keep up to date with progressive production and management methods? Then we have something that might just help – simply subscribe to the item blog by completing the box at the top right!

A high-performance, cost-effective solution for cleaning trays in the production process.

Reusable plastic workpiece carriers are used in production processes in a number of industries. These trays generally have to satisfy two primary requirements – they must, as far as possible, be free of dry contamination and electrostatic charges. Since workpiece carriers in different industries can have very different surface structures, cleaning them can sometimes be a complex undertaking. The often intricate geometry of grooves and notches that hold the workpieces in place offers a host of hiding places for dust and dirt. Electrostatic charges also build up on the trays due to their handling and movement during the production process or transport, which makes it even harder to get rid of the dust.

The importance of clean trays for product quality 

It was against this backdrop that a customer from the plastics manufacturing industry approached K&K Systeme, an item pluspartner. K&K specialises in turnkey solutions for factory equipment engineering, ionisation, temperature control, automation and robotics. In addition to the plastics industry, it supplies customers in the graphics, automotive and pharmaceuticals industries. In all these sectors, product quality is very dependent on high standards of hygiene. 

For the customer concerned, trays that were not completely free of dust and static would mean electrostatically charged dust particles could stick to the glossy surfaces during injection moulding. Since the optical quality of these surfaces must be spotless for further processing, contamination of any kind would lead to rejects. Similar requirements can be found in cosmetics manufacturing, where hygiene is key. Electrostatic discharge would be a further risk factor where electronic components are being manufactured or used, for example in the semi-conductor industry.

Requirements for cleaning workpiece carriers

The list of companies who could benefit from effective automated cleaning of reusable plastic workpiece carriers is long and wide-ranging. However, the basic design of any such cleaning system needs to be flexible enough that it can be adapted to suit the specific format of the trays in any given production facility. The system must also be capable of both cleaning the trays and neutralising the electric charge. At the same time, it must be easy to operate, so that it does not take several employees to clean the trays.

A frame built using components from our MB Building Kit System forms the basis for the solution K&K have planned and executed. What K&K values most about our products are their long service lives and modularity. Using aluminium profile technology makes the construction corrosion-resistant, electrostatically dissipative and suitable for flexible expansion, thanks to the open grooves. Rotating compressed-air nozzles are used for the vital cleaning process. These are able to reach into even the most inaccessible notches and brackets. The dust particles thus released from the trays are extracted and the workpiece carriers undergo an electrostatic discharge. Ionising the trays also reduces the risk of new dust particles settling on them.

The Kreuz-i RS600® tray cleaning system

After the first special build had proved itself by working double shifts for the customer over several months, K&K Systeme GbR decided to market the system and establish it as a firm part of its portfolio. It became the Kreuz-i RS600® tray cleaning system, which combines all the functions of the first model and can be simply and ergonomically operated by a single employee, making it ideal for automated industrial manufacturing processes.

With one employee working single shifts, the Kreuz-i RS600® can achieve an annual throughput of up to 1.5 million trays. Besides the basic model, a variety of modules are available to increase the level of automation. In the fully automated cleaning system, the employee only has to remove pallets of trays that have been cleaned and any electrostatic charges dissipated.

Are you interested in fascinating reports and innovations from the world of specialist mechanical engineering? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

Test equipment is part and parcel of daily life in university-based research. However, it also brings with it a recurrent problem.  

What do you do if you’re a researcher who is highly specialised in your specific field, but you lack the same degree of proficiency when it comes to getting hands-on with technology? It would make perfect sense to have a contact who can guide you through everything from advising on, planning and building systems, to providing the necessary software solutions and even analysing the results. This is precisely the kind of fully comprehensive package that Wesseling-based German company ZUMOLab GbR offers. The story behind this start-up is remarkable and is about much more than a simple case of supply and demand. In fact, it highlights the opportunities that the university environment offers start-ups. 

From scientific support staff to entrepreneurs 

As is so often the case in life, one thing leads to another... While studying at RWTH Aachen University and FH Aachen University of Applied Sciences, students Christian Moritz and Dominic Zuleger were also working as scientific support staff at the Chair for Chemical Process Engineering. The main tasks of the committed and enthusiastic pair was to support system planning and software engineering. “Ultimately, a lot of the test systems at the Institute were running on software that we had specially programmed,” recounts Moritz. That was why the up-and-coming programmers enjoyed strong support from their professor, who also encouraged them to take the uncertain step of setting up their own business. 

When they completed their studies in 2014, they didn’t need to think twice, and set up ZUMOLab GbR. Initially, the company focused solely on software solutions. As Moritz explains, however, they encountered an unexpected problem elsewhere during this period: “Right at the start, it became clear to us that it would be difficult to get financial support for the start-up. We fell through most of the funding programmes pretty quickly. It all came down to one thing – we were offering a service, not a product.” In the long run, that problem wasn’t enough to spoil the company’s success, since it had a dependable customer on board from the outset in the shape of RWTH Aachen University. Moreover, the quality came through.  

“Steel wasn’t an option...”  

The company’s work did not stop at simply developing software for test systems and experimental facilities. Before long, more and more customers started asking whether the team could also plan and build small test systems, too. From the customer’s point of view, that made perfect sense, but this kind of work posed a not insignificant challenge for the small company. How could they build test and experimentation systems without a workshop of their own? This is precisely where our MB Building Kit System came into play or, to be more precise, Profiles 5 and Profiles 8. Moritz explains: “We felt that item made the best impression in terms of quality.” 

Even while students, the two entrepreneurs had got to know our modular solutions at several teaching facilities in Aachen. “It was the MB Building Kit System that made it possible for us to design and assemble our own equipment. If we had been working with steel, we’d have had to outsource the construction work to a metalworking shop,” says Moritz. Due to their modularity, the item profiles were the perfect fit for the young company’s requirements. For example, the test benches can be adapted to new conditions very easily on site.  

Well prepared for the future 

At present, the customer base of ZUMOLab GbR is predominantly made up of higher education institutions. However, small and medium-sized companies are also starting to take advantage of the start-up’s services, particularly when they are working to high capacity and need support with software development. Since Zuleger left the start-up at the end of 2015 to join the sales team of another company, Moritz has been running ZUMOLab with his Dutch-born colleague Stefanie Kriescher. Thanks to the experience she gained from her doctorate in Aachen, she has brought additional know-how about the scientific community to the company. What’s more, she can also undertake programming tasks independently, as can her fellow Managing Director, who deals primarily with the software engineering for the test systems. 

Do you want to keep up to date about innovative ways that item solutions are being put to use? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

If you’ve ever been involved in project management, you’re bound to be familiar with Gantt charts. But who invented them?

Unfortunately, Henry L. Gantt (1861-1919) has slipped into obscurity somewhat. However, he was a busy mechanical engineer who did much more than just lend his name to a popular planning tool. Other ideas that he explored in relation to valuing individual employees, for example, were truly remarkable. This blog entry aims to fill in some of the blanks about Gantt and his ideas and may even help you see those prolific Gantt charts in a different light. 

A determined start 

Gantt spent most of his childhood in Baltimore and showed diligence and perseverance from an early age. For example, he completed his schooling at McDonogh School, whose former pupils traditionally had the best chances of securing a place at an Ivy League university (such as Harvard, Princeton or Yale). He, however, opted for nearby but prestigious John Hopkins University. After a brief period as a teacher at his former school he returned to university. He left Stevens Institute of Technology in New Jersey with a Masters degree in mechanical engineering. 

In 1884, at the age of 23, he started his career as a draughtsman back in his home town. Three years later, he was working at Midvale Steel under Frederick Winslow Taylor. Taylor was the author of Taylorism, a method that aims to boost effectiveness by controlling work centrally and breaking it down into numerous small steps. Incidentally, the exact opposite of this approach is Lean Production, which would later take the place of Taylorism. 

Gantt chart: A classic project management tool 

Later on, Gantt won great acclaim in specialist circles thanks to his books “Work, Wages, and Profits: Their Influence on the Cost of Living” (1910), “Industrial Leadership” (1916) and “Organizing for Work” (1919). He was highly respected as a consultant for general management issues and worked for the US government during the First World War. He died shortly after the end of the war, in 1919. Thanks to the invention of the Gantt chart, which is named after him and builds on work done by Karol Adamiecki (1866-1933), Henry L. Gantt is still a part of many lectures, training courses and projects to this day.

The advantage of the Gantt chart lies in how easy it is to understand. Various activities or work packages are listed one on top of the other on the left, while the corresponding bars on the right map out the duration of each activity on a horizontal timeline. If, for example, the half-way mark on the bar for project phase A overlaps the start of the bar for project phase B, this indicates that phase B can start as soon as phase A is half complete. Dependencies between project phases can also be depicted using arrows. 

Henry L. Gantt’s legacy

Although Gantt is known today primarily for this central idea, many of his other achievements are no less progressive. For example, he designed the “task and bonus system”. Under this system, workers receive a percentage bonus over and above their usual pay if they achieve a set daily rate of work. The faster they complete their work, the higher their additional bonus payment. Penalties for slower rates of work are expressly excluded. Gantt was about motivating people rather than putting them under pressure. Later on, he promoted the idea of rewarding managers when their staff achieved the set targets. An incentive had to be created to get employees to share their expertise. 

This increased the role of staff training. Gantt envisioned an end to the days of “coercion” and the dawning of the “knowledge” era – he was well ahead of his time. Today, with the advent of digitalisation, lifelong learning has long since become essential. Corporate social responsibility was another area close to Gantt’s heart that has risen to prominence again in recent years. His ideas live on today in the “Henry Laurence Gantt Medal”, which the American Society of Mechanical Engineers has awarded every year since 1929. The award honours distinguished achievements in management and social responsibility. As such, it recognises two key aspects of Gantt’s work – improving efficiency and living up to one’s responsibilities. 

Are you interested in fascinating people and events from the history of engineering? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

Internal material flows and intralogistics are key factors on the route to optimum production efficiency.

That is why many companies are using automated guided vehicles (AGVs) and continuous conveyors (internal conveyor systems) to introduce as much automation as possible into their intralogistics. Both these solutions require considerable investment and are often overkill for the logistics requirements of many small and medium-sized enterprises (SMEs). However, Götting KG has developed a small, fully automatic AGV for precisely such companies that moves small load carriers (SLCs) between storage racks made of item components and an item Karakuri intermediate store at the production site.

Automating small-scale transport tasks

The Kinetic Automat for Transport Enhancement (KATE) has been specially designed for payloads up to 50 kg. This means no special safety precautions need to be taken when using it. KATE travels directly over the floor surface, and the energy released during a collision is so low that an employee wearing safety footwear would barely feel the impact. All the same, the AGV can of course also be fitted with laser or ultrasound-based obstacle detection systems that bring KATE to a stop before it comes into contact with staff. Additional safety precautions such as these can help to overcome the initial reservations that many employees have with regard to AGVs.

After all, automation is a bonus for all staff, since only very simple and monotonous tasks are taken over that would otherwise use up all the time of one or two members of staff. Instead, these employees can focus on value-adding tasks. The driving/steering module in KATE communicates via WLAN with a control computer and the TransportControl system. TransportControl is operated directly in a web browser, with no plug-ins or additional software needed.

Optimising intralogistics with AGVs

The track guidance system of the AGVs also helps ensure a rapid return on investment for SMEs by using route markers that are stuck to the floor and transponders. As a result, there is no need to take up the floor to lay the guide wires often used by similar systems. All these features convinced a shared customer of item and Götting to replace its ceiling-mounted belt conveyor system with small AGVs.

The aim of this switchover was to significantly reduce handling in production. KATE picks up an SLC from a rack system in the warehouse and automatically conveys it to an intermediate store, so that all employees have to do is load their machine. KATE also automatically picks up empty SLCs from the intermediate store and returns them to the warehouse. As a result, the AGV takes care of all material supply and removal tasks. Thanks to software and sensors, the supply of materials can be controlled automatically, completed at fixed intervals in accordance with plans or even initiated manually by staff at the intermediate store, e.g. using a tablet.

Customised item racks and Karakuri solutions

To ensure full automation can work in practice as it does in theory, companies need rack systems that can be adapted to suit the specific transport task. Götting KG identified a number of critical factors, including the huge selection and rapid availability of item components and the benefits in terms of simplicity and speed that a modular system offers when building bespoke customer solutions. Other important plus points were the high quality of the aluminium profile technology and the long-term stability of the fasteners. Indeed, it is crucial that automated material flows in three-shift operations can be run on a long-term basis without the need for major additional maintenance work.

However, as a specialist primarily in AGVs and the conversion of conventional vehicles for driverless use, Götting KG was reluctant to build the necessary rack systems itself. The customer’s requirements were therefore passed on to the item site in Hannover, where the bespoke solution was planned and engineered. Since they use our modular building kit systems, the rack systems can be perfectly adapted to the shape, length and sizes of customer containers.

Putting AGVs to the test at the Hannover Messe trade fair

In practical terms, the requirements for the resultant AGVs were as follows: Four different components, which are stored in SLCs at the company, are needed at a machine. The pick-up points in the warehouse are programmed into the AGVs. A lifting table and a driven roller conveyor are the only active elements involved. 

After collecting the material from the warehouse rack, KATE automatically travels to the machine at the intermediate store with the relevant four compartments. The small automated transport unit selects the correct compartment for the material it is carrying and transfers the material via a passive Karakuri solution, taking back an empty SLC and then returning this empty to the warehouse.

Want regular updates on the latest exciting applications to use our solutions? It couldn’t be easier, simply subscribe to the item blog by completing the box at the top right!

“You can never be ‘lean enough’.” An interview with our lean production expert Stefan Armbruster. 

When crates and workpieces in production seem to move by magic, it is often low-cost automation – also known by its Japanese name Karakuri – that is at play. We asked our expert on lean production, Stefan Armbruster, how companies can make the most effective use of mechanical automation and what kinds of perils and pitfalls they need to watch out for. He is also a regular contributor to the “LCIA and Karakuri Kaizen®” seminar at the CETPM Institute run by Ansbach University of Applied Sciences.

Why should companies utilise low-cost automation?

As an integral component of the lean philosophy, Karakuri solutions help avoid many types of waste in companies. When companies really take continuous improvement and the fight against all types of waste seriously, they almost automatically arrive at the point of asking how they can further increase a worker’s contribution to value creation. You can’t be happy with the status quo. You can never be ‘lean enough’. Continuous improvement means wanting to get better and better all the time. Karakuri is one way to get better.

How does mechanical automation help deliver improvement?

There are lots of processes that you sometimes simply can’t improve on without some extra tools. To ensure staff are spending more time on activities that add value, you need to think about automating repetitive tasks. Having people lift and shift crates almost always results in waste.

Is automation worthwhile for such simple tasks?

If productivity increases it pays off very quickly, so long as the mechanical systems are not expensive. In the case of improvements in car making, a time saving of 0.05 minutes is quite possible. Karakuri is about applying the methods of lean production to automation. You can achieve astounding results with pretty simple means. 

What is the difference between mechanical automation and electrical automation?

On the one hand, the difference lies in how fast it can be implemented. A traditional automation project lasts months and requires a huge budget. A Karakuri solution can be put together in a few days and costs just a fraction of a traditional automation solution. On the other hand, you need fewer parts and no electricity, sensors, controllers or programming – i.e. no specialist expertise. That means low maintenance costs, because staff can fix a fault themselves. The plant won’t grind to a halt while everyone waits for an expert to turn up with his laptop.

It sounds like mechanical and traditional automation are opposing forces.

Quite the opposite in fact. Depending on the task at hand, they can complement each other very well. Low-cost automation uses a combination of muscle power, leverage and gravity. All the same, there’s no getting around the laws of physics. If there is no other solution, you have to revert to traditional drives. In fact, that’s often essential when it comes to lifting heavy loads or moving loads very high up. One typical case is when components need to be lifted over logistics routes to get to the workstation.

When building hybrid Karakuris, it’s important that the logic component is moved into the mechanics so that the number of sensors and controllers can be minimised. Think of it like a grandfather clock, where the drive is merely responsible for pulling the weights back up. The drive starts when the weights are at the bottom and then pulls them back to the top. All the complex functions such as the hands that show the time and the striking mechanism are controlled by the mechanics of the clockwork. Both systems are entirely independent and can be separated from each other again quickly. 

OK, so this is my first Karakuri. What’s the best way to get started?

By trying things out. In our training courses, we start with a fun task such as redirecting a force from A to B in at least 10 seconds. Participants have to think about what type of movements they can use to reliably achieve this time delay. On the surface of it, the “what-happens-then” machine is a bit of fun. However, you develop virtually all the principles you will need later on to complete a genuine task quickly and efficiently. It is only at the end of this course that participants put together a simple small load carrier handling system.

Does Karakuri just fall into place?

The advantage is that you can achieve a lot with simple means. You can also work everything out for yourself, as long as you have enough time. Naturally, one of our training courses also offers the benefit of our experience, such as in how to handle rising and falling counterforces. Of course, people may well work that out for themselves over time, but the learning curve is steeper when someone shows you how. 

How is a training course conducted?

We often use an external teaching factory because it has everything we need and helps avoid disruption to production operations. We also offer on-site training courses for larger customers. When there is a very specific problem to be overcome, it’s essential to work with the actual crates and components that are involved.

What kind of mistakes have you seen people make when implementing Karakuri for the first time?

Lots of people try to develop the mechanics on paper first. That almost always goes wrong. It’s much better to take the workpiece, build a prototype and continuously refine it. That’s the power of continuous improvement. When you start by designing a CAD model, build everything then find out that a flap won’t move because of friction, you’ve wasted a lot of time. If you start with the flap and try it out straight away, you’ll have less rebuilding to do further down the line. 

A CAD model should only be drawn up later on, i.e. when the Karakuri is in proper working order. This makes it the “A” for “Act” in the PDCA cycle, which in this case means documentation or standardisation.

Why shouldn’t companies just buy in Karakuri solutions like they do with automation solutions? Won’t they save even more time that way?

From a management point of view, that sounds tempting, but it’s bad for the motivation and expertise of the workforce. We’re talking about continuous improvement. If a team has developed something itself, it can also repair and continuously refine the application itself. Try it out with an external solution or with a programmed linear unit. 

In the long run, the expertise will be a real gold mine for two reasons: Firstly, because the fight against waste goes on. And, secondly, because staff develop the skills to apply the principles of Karakuri to other issues. If you can see opportunities and utilise them straight away, without having to wait around for an investment decision, you will benefit the most from lean production.

The Toyota formula for the value of a company is also a good indicator. The formula is: 

Company value = number of employees x skills x motivation 

You need fewer employees to order a solution than to develop it. The employees’ skills do not need to be developed and nobody is motivated, either. Ultimately, that reduces the company’s value.

Where do the ideas for Karakuri projects come from in the company?

Allow me to answer that with a question: Who is responsible for quality in a company? Who is responsible for success? In lean production, there can be only one answer – everyone! Every employee is responsible and every employee can come up with that all-important idea for how to make something better. It doesn’t have to be an engineer or one of the workers who builds the factory equipment.

What constitutes a good Karakuri building kit system for companies?

Karakuri is not a discipline in its own right, but rather an element of lean production. A good Lean Production Building Kit System will contain suitable components. These must be low-maintenance and self-explanatory. The components shouldn’t require any special machining or special tools. Ideally, a saw and a hex key should be all that is needed. It’s also essential that elements can be adjusted and replaced quickly.

The building kit system should also contain all the components needed to ensure moving assemblies can be built safely and reliably. Such components would include pivot bearings, bushings, castors, roller elements, roller conveyors, etc. What’s more, it’s crucial that staff have access to parts that enable low-friction movements. This is essential if mechanical assemblies need to be actuated by light components (such as empty small load carriers). 

Besides, Karakuri is not necessarily linked to a building kit system. When it comes to handling the smallest of parts, companies may need to manufacture special components that have been optimised for this purpose.

What are the limits to Karakuri?

Since we’re talking about simple mechanics, anything is possible in theory. In practice, not everything is feasible. You could, of course, develop a Karakuri to turn concrete slabs. The only problem is – how expensive would that be? Massive systems like these aren’t easy to modify either, meaning they aren’t automatically CIP friendly.

Nonetheless, there are exceptions here, too. For example, there are ingenious Karakuri solutions for changing the heaviest of tools that pay for themselves very quickly, even despite their complex design.

Are you always on the lookout for the latest news from the world of lean production? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

How reorganising an assembly line boosts productivity by up to 30 percent. 

Improving the productivity of manual assembly work is a key factor for remaining globally competitive. Anyone who fails to harness the many benefits of lean production approaches such as the one-piece-flow concept will quickly fall behind. A medical technology customer who was well aware of this fact asked item pluspartner Plan B to build it a new assembly line. Founded in 1998, Plan B has become a globally oriented all-rounder in specialist mechanical engineering. 

Both lean and ergonomic 

The customer required an assembly line that enables it to optimise workflows and cut both throughput and manufacturing times. The new system needed to be sufficiently flexible to manufacture several products on a single line. An ergonomic workplace design was also considered important. Faced with a wide choice of production systems, the customer had difficulty finding the ideal solution. After examining the complete requirements profile, Plan B suggested using a U-shaped assembly line and converting production to the one-piece-flow principle. 

Production based on one-piece-flow principle 

The one-piece-flow principle – also called an “employee-centred workflow” – was implemented for the first time in the Toyota production system. The ground-breaking idea was for one employee to work on each production part in a given assembly process until it is finished. On the customer’s new assembly line, the various products are now also made at fixed workstations according to defined schedules. 

One employee starts at the first station of a cell and accompanies a production part in a continuous production process from station to station. As soon as the product is finished at the final station, he repeats the process from the start. A U-shaped arrangement of the individual assembly stations – the U-line – is an ideal solution for locating the start and end points of a cell as close together as possible and simplifying communication between staff. Good previous experience with the flexibility and strength of our solutions led Bremen-based company Plan B to use our Profile Tube System D30.  

Entire assembly line benefits from lean production

One key benefit of the assembly line designed according to one-piece-flow criteria lies in the fact that stocks of semi-finished products are reduced, as are throughput and manufacturing times. A further positive aspect of the one-piece-flow principle is that employees learn to perform all processes at the various workstations. This makes assembly processes more varied and the customer’s staff are more motivated. 

Overall, the many advantages of an assembly line of this kind easily achieve a productivity increase of up to 30 percent. Plan B’s customer also found that the proportion of value added per employee rose significantly. What’s more, less reworking was required and there were fewer quality problems. Another of the system’s plus points is its flexibility. The individual modules in the U-line can be extended or modified on an ongoing basis, which means the item pluspartner’s customer is now using an assembly line that is also equipped for future challenges.

Are you interested in fascinating reports and innovations from the world of lean production? Then we have the perfect solution for you – simply subscribe to the item blog by completing the box at the top right!

How a clever idea and the benefits of our building kit systems come together to create bespoke, innovative cargo bikes.

Burgeoning urbanisation in most industrial nations is changing the face of urban traffic. Once the first choice for all forms of private transport, today the car is often relegated to second place behind the cargo bike when it comes to getting the kids somewhere or doing the weekly shop. Long before the current trend took hold – one that is now being served by a wide range of suppliers – Sven Bastiaen Schulz decided to build his own cargo bike. Since then, he has continued to build on his initial idea.

The optimum child transporter bike

Although his first model, designed for his own personal use, was cobbled together from old bits of scooters, the feedback he received from both friends and strangers quickly highlighted the huge potential of his design. However, it was also clear he would have to meet far more stringent requirements in terms of material quality and production conditions. The ultimate aim was to produce a lightweight, manoeuvrable cargo bike with single-sided front wheel suspension, like that on a car.

A design such as this, which doesn’t have a fork to get in the way of things, offers numerous advantages. In a direct comparison – including with many commercially available cargo bikes – the item cargo bike can carry up to 50 percent more cargo and is almost 20 percent shorter and lighter at the same time. What’s more, a seating unit or child seat can be integrated so that children can sit face-to-face with their parents while they ride. As there is plenty of space for a transport crate under the seat, there’s also no need to make that tough decision between carrying your kids or your shopping, either...

Manufacturing cargo bikes

Efficient production operations require the use of special tools and cutting-edge manufacturing processes. Examples include the pressing tool for the front wheel and the use of laser-cut tube sets that are uneconomical for a single example. When the prototype produced in 2015 and exhibited at a trade fair in Berlin in 2016 met with a very positive response, a plan was set in motion. A small series of ten cargo bikes would be produced as an initial run, using production equipment that, on the one hand, would have to be cheap enough to make such a small run worthwhile and, on the other, would have to support the production of longer runs.

A frame gauge is an important design tool for all bike builders. Frame gauges are used to precisely position all the individual tubes before they are finally fused together to make a frame. To ensure different frame variants can be produced and that the bike frames can be subsequently removed, it is important that fixings can be repositioned. However, even in countries with cheaper labour costs than Germany, welding together custom designs like these would have cost € 5000 if sent to a framebuilder. 

Frame gauges made using the MB Building Kit System from item

Instead of having frame gauges welded together, Sven decided to make them himself, using components from the item MB Building Kit System. This solution proved so cost-effective that it paid for itself over the planned short run of ten cargo bikes. And, of course, there was no compromising on functionality, either. Last-minute changes to the geometry of the frame so as to modify certain angles or mount a longer loading platform don’t present any problems when using the MB frame gauge. 

This also offers customers very tangible benefits. Thanks to the use of this professional frame gauge and laser-cut tube sets, the frame has become much more geometrically complex and yet easier to build compared to the prototype, which was built virtually by eye. This has helped reduce build costs and improve ride characteristics.

Custom attachments thanks to Profile Tube System D30

After resolving the issue of a suitable frame gauge, the next step was to look at the bike’s functionality and the custom attachment designs. Here, too, the item cargo bike had to stand out from off-the-shelf alternatives. From the very start, the frame had been designed to accommodate not just the tried-and-tested transporter box with integrated child seat, but also custom loading platforms that could be built using Profile Tube System D30. Simply insert two cross-profiles through the frame and you can continue building on them. This gives customers maximum flexibility, including when it comes to carrying interchangeable containers. 

Another element that is always useful when you’ve dismounted your cargo bike is a twin-leg kickstand, although the cost of manufacturing a component like this is usually prohibitive for such a small production run. The solution was to make the kickstand from the stable D30 aluminium system, too. Naturally, exactly what a cargo bike based on the building kit systems from item can do depends first and foremost on what potential customers want. If you like the sound of the item cargo bike, you can contact the manufacturer using the following details:

Sven Bastiaen Schulz
Maarweg 29
53123 Bonn
Germany

+49 (0)174 2034160
http://www.bastiaen.de
sven@bastiaen.de

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help: simply subscribe to the item blog by completing the box at the top right!

Thanks to the new online tool, profile technology and the corresponding connection processing can be ordered more easily and much more efficiently – from anywhere.

Development work on the item Machining Tool centred on a problem that has existed ever since aluminium construction profiles were invented: How do you combine the processes of specifying, documenting and ordering profiles and machining services in one single process?

In the past, customers first had to create complex drawings by hand or correctly describe cryptic codes or supposedly self-explanatory article numbers. Profile technology suppliers were then tasked with deciphering this information and converting it into bills of material for production. Alternatively, profiles and machining services could also be lodged in the CAD system, but that didn’t really save a lot of time. All in all, putting together all the documentation, first for the customer enquiry and then for production, was a complex task and nobody could afford to make a mistake at any point in this manual process.

Choosing the perfect aluminium profiles

To further complicate matters, the above description doesn’t even touch on the crucial matter of picking the best possible profile for the engineering task at hand. Entering the relevant customer features in the item Machining Tool immediately narrows down the overview of all possible profiles to a selection of suitable candidates. The Tool even takes care of calculations and shows which profiles satisfy the requirements for profile deflection – as per the relevant length and force specifications. The precise values of the calculation are also shown. With this as a basis, users can easily work out which of the selected profiles are best suited to their construction.

If there are several matches, additional filters can be used to refine the result. This means, for example, that all products other than certain lines or very specific profiles can be taken out. This delivers an optimum mix of cost-effectiveness and efficient use of materials. Indeed, filter customisation options combined with integrated calculators are a very effective means of avoiding over and undersizing. In technical terms, the Machining Tool is based on cutting-edge Web technology, which means it doesn’t need to be installed, doesn’t rely on a plug-in or app and can be used on any PC, smartphone or tablet.

Includes profile machining and project documentation 

Another advantage of the state-of-the-art technology behind the tool is that the profile is shown in a 3D view that can be freely rotated and scaled. Also included is a selection of fasteners that can be added directly to the 3D drawing via drag & drop functionality. The integrated logic ensures fasteners can only be positioned at locations where it is technically possible to install them. During this same step, all the connection processing types such as through holes, stepped bores and threaded bores are automatically and accurately positioned as appropriate to the relevant fastener. Creating a 3D model like this in a CAD system can easily take several minutes, but the same process using the item Machining Tool can be completed in a matter of seconds.

Integrated project documentation is also part and parcel of this efficient end-to-end concept. Once the configuration process is finished, complete project documentation is automatically compiled to document all positions and dimensions in a technical drawing. This drawing is then automatically generated by the system with just a single click so that all information is available for high-precision production operations.

Place orders directly from the item Machining Tool

To round things off nicely, the Machining Tool is also integrated into the item Online Shop, which saves even more time. After logging in, business customers can see the value of the machined profile straight away and order it online – along with fasteners and accessories, if they wish. Project data is transmitted in seconds and the precision-machined profiles can be dispatched within 72 hours.

Simple and efficient in every step

The item Machining Tool makes the most of all the advantages offered by digitalisation in every single step of the profile ordering process – from the idea to the machined profile of choice. As a user-friendly online tool, it ensures efficiency in day-to-day engineering work, cuts costs and saves time, too.

Disclaimer: The item Machining Tool is available only in German right now. An English version will be published soon.

Do you want to keep up to date on how digitalisation is simplifying your engineering work? Then we have something that might just help: simply subscribe to the item blog by completing the box at the top right!

22 March 1897 was the day that Germany’s tallest iron railway bridge was topped out – and it has retained that title to this day.

The statistics for the Müngsten Viaduct, which connects Remscheid and Solingen, are impressive. It is 107 metres high and 465 metres long, weighs 5000 metric tons and its stability is ensured by, among other thing, 934,456 rivets. However, when the statistics reach such dizzying heights, you have to wonder how the structure fits in with its surroundings. In the case of the Müngsten Viaduct, that isn’t a problem. The bridge is a spectacular sight that is close to the hearts of everyone in and around Solingen, including us! But that’s not all – the Müngsten Viaduct Park, which opened in 2006, has long been a firm favourite daytrip destination. The bridge is a testament to the history of engineering in Germany and a treasured part of our identity as a Solingen-based mechanical engineering company. 

Innovative engineering for the Müngsten Viaduct 

All aboard! Next stop, the 19th Century: We’re standing in the middle of the office belonging to Anton Riepel (1852–1926), one of the most renowned engineers of his day. He is sitting in front of a pile of documents, looking a little rueful and sketching away tirelessly. What’s he up to? He’s grappling with a project that he and a lot of his colleagues have been working on for years. When the bridge – originally called the Kaiser-Wilhelm Viaduct – was opened, eight years had elapsed since the first plans were drawn up. It was in 1890 that the state approved the sum of five million marks initially proposed for the building work. However, this was no showpiece project, as was clear from the circumstances at the time. Indeed, although Solingen and Remscheid are only 8 kilometres apart, getting from one to the other by rail meant travelling a total distance of 42 kilometres. 

Building an iron viaduct was the logical solution. The Müngsten Viaduct was built using an innovative but complex technique, so it’s no wonder that Riepel worked up a few worry lines. The technique in question is the cantilever method. That means the two halves of the main arch on the Müngsten Viaduct were built in their entirety, right up until their completion, without any additional framework. They were able to support themselves because they were anchored at one end, which also saved a great deal on materials and costs (the viaduct ended up costing just 2.64 million marks), but required a lot of complex calculations before work could start. The effort certainly paid off, and Riepel and his Müngsten Viaduct became pioneers of this innovative technique. 

Big plans and lots of fun in Müngsten Viaduct Park

But let’s return to the present. If you’re impressed by the Müngsten Viaduct, then please join us in keeping your fingers crossed. The three cities of Solingen, Remscheid and Wuppertal are currently working hard in partnership to have it recognised as a UNESCO World Heritage Site. It is hoped it can be declared a transnational World Heritage Site along with similar bridges in Porto and Auvergne. Müngsten Viaduct Park is a car-free conservation area created around the viaduct that is home to varied wildlife such as the protected kingfisher. 

If you want to explore a fascinating example of engineering and indulge in some outdoor pursuits, you should try out the overhead ferry. Passengers on this very special mode of transport, which operates on the drainage principle, use their own muscle power to cross the river from Solingen to Remscheid and back again. You could say that this “natural” form of automation has a lot in common with Karakuri. Of course, after all that exertion, you’ll need some sustenance, and Haus Müngsten restaurant has plenty to offer, not to mention an impressive commitment to social principles. As an inclusive company, it offers unemployed people with disabilities job opportunities and sets an outstanding example for others to follow. 

Do you want to keep up to date about the world of item? Then we have something that might just help: Simply subscribe to the item blog by completing the box at the top right!

Once again, 15 March this year will be all about back health, featuring events, campaigns and workshops.

The Campaign for Healthy Backs (AGR e.V.) and the Association of German Back Schools (Bundesverband der deutschen Rückenschulen (BdR) e. V.) traditionally organise “Back Health Day” in mid-March. While last year’s focus on ergodynamics was about encouraging employees to pursue a lifestyle that is healthy for their backs, the 16th campaign day will highlight the role of balance – both physical and psychological – in maintaining back health. There will also be lots of valuable information about work bench ergonomics. 

Back Health Day and its importance for SMEs

Back pain is an issue that is not restricted to office workers. For many years, a key part of the campaign day is underlining the importance of back health for industrial companies. Back pain is still one of the most commonly suffered conditions, and is one of the principle causes of people being unable to work in Germany. With an average of more than 15 sick days, musculoskeletal disorders are among the illnesses that cause the lengthiest absences. SMEs can be particularly hard-hit by these kinds of absences, especially as they generally affect experienced employees.

The current AGR back report shows a clear trend – nearly 70 percent of respondents indicated that they had problems with their backs at least once a month. For some time, this group has also included younger workers who still have a long working life ahead of them. And yet, according to the AGR, 90 percent of these complaints are not caused by serious conditions. Indeed, in most cases, back problems are caused by employees adopting and holding a lop-sided posture for long periods, as is often the case during manual assembly work. Industrial work benches that cannot be adapted to the individual physical requirements of employees also represent a risk. Under these conditions, it quickly becomes clear that work bench ergonomics pays.

Work bench ergonomics as a competitive advantage

In an interview, ergonomics expert Ulrich Kuhnt went a step further – “Companies that don’t implement ergonomics will not be able to survive in the long term”. In fact, ergonomic industrial work benches do more than reduce sick days, they also put employees in a position where they can achieve the best possible results based on their own specific needs. Work bench ergonomics is therefore key to increasing the production efficiency of a company, particularly when it comes to manual assembly work.

The close interplay of ergonomics and lean production can also be seen in another example. In a one-piece-flow process, employees accompany a single workpiece through every processing step all the way to completion. This reduces both lapses in concentration caused by constantly repeating the same work steps and the muscular imbalances that see certain muscle groups subjected to a great deal of strain as a result of monotonous, long-term stress, while other muscle groups are virtually unused. Pain and, in the long term, sick days are the consequence when work bench ergonomics are disregarded. 

Campaign calendar for the 16th Back Health Day

This example brings us full circle to this year’s motto – “Find your balance – strengthen your back!”. Of course, putting in place ergonomic work bench design will not completely eradicate back complaints on its own. That is why Back Health Day always aims to provide information about preventive measures employees can take themselves. 

The 16th Back Health Day is therefore accompanied by a wide range of events, offers and campaigns. All over Germany, a large number of doctors, sports clubs and fitness studios are taking part throughout the week with special campaigns relating to back health. All the official events are marked on an interactive map of Germany. 

Would you like to keep up-to-date with the world of work bench ergonomics? Then we have something that might just help: Simply subscribe to the item blog by completing the box at the top right!

A concrete way of achieving continuous improvement. 

Lean production has become firmly established – and that’s true in Europe, too. The idea of doing away with entrenched thinking and paying attention to seemingly minor details has breathed new life into industrial production. The lean philosophy also gives greater appreciation to individual employees – after all, they are the ones who know best where waste is produced. Sometimes, though, the crowd of abstract jargon, often virtually incomprehensible, can obscure the view of what the lean movement is actually about. To prevent this, the focus of this blog entry is the PDCA cycle, which illustrates how processes can be optimized. 

The PDCA principle – a firm part of CIP  

How the PDCA cycle works 

The Deming cycle – a roundabout way to success 

The fourth industrial revolution is also transforming the education/training and labour market.

All good things come in threes – or should it be fours? So far we have looked at the general principles of Industry 4.0 and its close links with ergonomics. The third part of our series about what is probably the key transformation in the industrial working environment focuses on education and training. Due to the complexity of this issue, changes are taking place in many different ways. Content-related changes are going hand in hand with fundamental changes to educational establishments/training centres and knowledge transfer. A number of questions need to be addressed. What is the best way of representing these complex changes in vocational education and training? Will entire occupational profiles change, for example? And what are the options for employees who have been in their professions for a long time?

Industry 4.0 in the world of training and education

“Digitisation is leading to fundamental changes in education and training. Our aim is to work together to actively shape this process,” says State Secretary for Education and Research Cornelia Quennet-Thielen. The December 2016 policy document of the Standing Conference of the Ministers of Education and Cultural Affairs on education in the digital world explicitly addresses issues such as the Internet of Things and smart craftsmanship. As the digital education/training monitor reveals, however, there is still some way to go in terms of implementation. According to the surveys referred to, a great many people working in education remain to be convinced by forms of digital learning involving apps and interactive whiteboards. 

Less qualified young people, on the other hand, are enthusiastic about digital learning. The study concludes that digital learning options could greatly motivate this group and help improve their chances of advancement. This aspect is a further indication of the potential of Industry 4.0 for actively shaping the future. Higher education is no exception. Admittedly, there is no dedicated study programme for Industry 4.0 based on express collaboration between various disciplines. This would not do justice to the complexity of the different programmes. It is therefore up to courses to adapt accordingly. The fourth industrial revolution makes its presence most felt in mechanical engineering, electrical engineering and IT. The main courses in these fields offer many different options for looking more closely at the new technological possibilities.

Vocational education and training 4.0 – a key political issue 

The German Federal Ministry of Education and Research has also responded to this rapid development. In 2016, it published a guideline for funding digitisation at inter-company vocational training centres and competence centres. It is a well-known fact that the aspects of training and education that cannot be carried out at the relevant company take place at inter-company vocational training centres. By 2019, these centres are to benefit from funding of up to 74 million euros. There are two aims here. On the one hand, educational establishments and training centres can apply for selected equipment (such as 3D printers or robot assistants). On the other, pilot projects will take place to test the success of new digital learning methods. 

Digitisation in the world of work 

In view of digitisation, labour market experts generally recommend having as broad a knowledge base as possible. A mechanical engineer who is also well versed in areas such as data security or artificial intelligence has good job prospects – not only due to the skills acquired but also in terms of easier coordination with colleagues from other departments. The keyword here is interdisciplinarity. Concepts such as the smart factory with its cyber-physical systems (CPS) or the use of collaborating robots require a fundamental rethink. This does not mean humans would be downgraded as is often assumed, though. Quite the opposite in fact. New, creative work methods are emerging and the range of activities is growing all the time. 

As already mentioned, engineers need to expand their IT know-how and, conversely, IT specialists must pay even greater attention to specific application contexts in industry. The individual disciplines can only benefit from this. Despite ongoing task development, humans are by no means being eliminated. The foundation has been laid for preparing young people for the consequences of digitisation. But what about those people who started out on their careers in the analogue world? Lifelong learning is the key here. Numerous further training measures and associated recommendations are offered, for example, by the knowledge forum of the Association of German Engineers and by the German Federal Ministry for Economic Affairs and Energy. So there has been no change to the basic principles for a long working life – proactivity and a thirst for knowledge. 

Are you interested in the impact of Industry 4.0 on mechanical engineering? Then we have the perfect solution for you. Simply subscribe to the item blog by completing the box at the top right!

How Lenkering GmbH found an innovative solution to a long-standing problem.

Custom assembly work benches are perfectly adapted to the steps in the relevant process. One inevitable downside of this, however, is their inflexibility, with a typical annual capacity utilisation of between just 20 and 40 percent. That leaves a lot of room for improvement when it comes to cost-efficiency. Dennis Lenkering, Managing Director of Lenkering Montage- und Zerspanungstechnik GmbH in Steinfeld, in the German region of Lower Saxony, was determined to do something about this. He worked with the in-house design team to devise a whole host of different approaches and one proved a winner. The modular MP EcoLine^® series was released just six months later. 

It is no secret that German SMEs enjoy an enviable reputation worldwide for their values and quality standards.

The universally recognised symbol of a “German engineer” or the phrase “Made in Germany” speaks a clear language and represents a seal of quality. However, it can sometimes be easy to lose sight of all the major international projects where German SMEs play a vital role. After our presentation a few weeks ago of the clean room technology in the billion-dollar European XFEL project deep underground, we are now taking to the skies. The question is how to further improve the design of materials for aircraft construction. 

Aircraft construction at Airbus 

The aerospace industry operates under extreme conditions – timelines are tight, and the material has to withstand extreme environmental conditions. There is simply too much at stake – especially in the fuselage and wings – to make even the slightest compromise. This is why composite materials are generally used in this case. You have to imagine a composite material like this – you take at least two very different materials and combine them, creating a new material with its own unique characteristics. One special kind of composite is most common in the aerospace industry – sandwich construction. This involves surrounding a soft core with two hard outer shells. 

This method has one downside, however. Material created in this way is very expensive and also exhibits a high level of sensitivity. French aircraft manufacturer Airbus therefore employs Dr. Gregor Endres’ innovative tied foam technology. This uses a fully automatic sewing machine from Schmohl Nähautomaten GmbH. Based in Filstal in the Swabia region of Germany, this specialist in sewing assembly lines has been using our profile technology for quite some time, and is also a member of our item pluspartner network. Schmohl especially trusts in item’s high quality standards and excellent customer service. In the STINGTECH process, the needle of the Schmohl machine penetrates the foam from the outside, picking up a loop of roving material. The rest of the material is cut off. This creates the preform of the material. Every stich is placed based on a complex mathematical model – with millimetre precision.  

Tied foam technology – not just something for the aerospace industry 

Further processing involves casting resin, which is spread over every thread. This creates an exceptionally robust hold that can withstand a lot of damage. The flexibility of the tied foam technology is also outstanding. Both synthetic and organic textiles can be used. Synthetic textiles include carbon fibre and glass, for example.  “The design options are also pretty much unlimited,” says TFT creator Dr. Endres. In addition, his invention is perfect for use in shipbuilding, wind turbine construction and general construction.

Would you like to receive direct information about innovations from the world of specialist mechanical engineering? Then we have the perfect solution for you: simply subscribe to the item blog by completing the box at the top right!

The new sales and production centre in Solingen gives item even more flexibility for rapidly reacting to customer requirements.

In December 2016, item opened a brand new site in Solingen’s Piepersberg business park as part of a major investment package aimed at optimising its in-house processes. The item Piepersberg sales and production centre combines the two crucial areas of indirect and direct sales under one roof close to headquarters. 

One contact point for all item products

It is not just the initial team of 150 employees at the site who will benefit from having everything much closer to hand, as customers can now also find the entire product range in one central location. Inbound and outbound deliveries are much more straightforward thanks to the virtually direct link to the A46. This convenient geographical situation also helps speed up order preparation, which means that custom profile sections can be manufactured and supplied even faster. With 5,000 small parts available at all times, 1500 metric tons of lengthy products and 120 panels, item Piepersberg is also the first pick-up point for customers in the region who want to collect their orders.

Outstanding delivery reliability thanks to cutting-edge logistics

To help keep track of all these volumes, the sales and production centre is using the very latest in automation technology. Here too, the statistics are impressive – the automated warehouse facility comprises 45 individual storage areas, 1,600 long load containers and 30,000 crates for small parts. The adjoining pallet warehouse has an additional 3,100 storage spaces. This focused and efficiently coordinated logistics means that customers in Germany can be supplied with goods within 24 hours. The delivery time for cut-offs is 48 hours.

These turnaround times are made possible by two panel saws that are fed directly from the automated panel warehouse by a gantry system with a vacuum gripper. The Piepersberg site also has a fully automatic saw for long aluminium goods that features an infeed and removal table. The outdoor storage facility covers 3,000 m², can be navigated by trucks and offers the ideal conditions for getting item components sent out fast. It also includes a waiting area that can accommodate up to four trains and a container set-down area.

The big project in brief

Before all this was possible, the project team at item had to overcome a number of challenges. At the start, item Piepersberg was not much more than a 67,000 square-metre open space. Equivalent in size to nine average football pitches, there was a lot of groundwork that had to be done before the sales and production centre could rise from the earth bit by bit in the space of a year. Just under 115,000 m³ of earth was excavated. Some of that was reused as backfill while the remaining 90,000 m³ was transported away – enough earth to fill almost 6,400 articulated lorries.

At peak times, there were around 200 construction workers on site. One important goal of the entire project was to work with companies from the surrounding region. For example, item Piepersberg was planned by Solingen-based architects Volker and Mirjam Hoch. Some 140 km of electric cables snake through the sales and production centre, while the photovoltaics on the roof generate 130 kW of power. The first stage of the project, which is a major investment in the future of item, has delivered a storage and production site that covers around 21,000 square metres, and this is to be extended with another 2,800 square metres of office and showroom space. All in all, the Piepersberg site offers plenty of scope for pooling even more products and services in the future.

Want to keep up to date with everything that’s going on in the world of item? Then we have something that might just help: simply subscribe to the item blog by completing the box at the top right!

How two engineers from Thuringia want to create affordable homes in developing countries and crisis-hit regions.

Sand is one of the most important raw materials on Earth. For example, it is a crucial ingredient in concrete and thus a bedrock of modern housebuilding practices. But not all sand is the same. The grains of sand that is used to make concrete need to be big enough to bind properly with the other ingredients. Desert sand is actually unsuitable because it is ground down by being in constant motion due to weather conditions. However, a piece of highly innovative engineering from Germany is turning this very material into an extremely versatile building material. 

Modular kit system for housebuilding

Working in collaboration with the Chair of Building Chemistry and Polymer Materials at the Bauhaus-Universität Weimar, Thuringia-based Polycare Research Technology GmbH has developed a process that involves adding an unsaturated polyester resin and additional additives to desert sand to produce a viscous compound with a curing time of just 20 minutes. Fully cured after 24 hours, the compressive and flexural strength of the polymer concrete can be up to five times greater than that of cement concrete, depending on the composition of the filler material. However, the principal aim of engineers Gerhard Dust and Gunther Plötner was to “help people help themselves” in regions where safe accommodation is scarce. 

It was therefore important that the building material can be used by untrained people with no access to construction machinery. Polycare meets this requirement with its Modular Assembly System (MAS). While it is still in a viscous state, the polymer concrete is poured into one of five basic moulds, where it cures to form blocks that, at first glance, look very similar to LEGO^® bricks, and indeed work in the same way, albeit on a larger scale. But besides its modular design, the concept also shares another similarity with our MB Building Kit System. Cavities inside the modules are used to bolt together individual layers for stability, which means they can subsequently be disassembled in a non-destructive way, so that the blocks can be reused elsewhere.

A sand house a day

Even the machine needed to cast the components was designed with mobility in mind, ensuring it can be transported easily and set up close to the building site. The plant has been successfully tested with sands of various grain sizes from Namibia to North Africa. Moreover, in crisis-hit areas, filler materials can be sourced from the demolition of destroyed buildings, for example. The necessary additives such as the special resin only make up 10 percent of the polymer concrete, which greatly simplifies logistics operations.

A single plant can produce approximately 16 metric tons of polymer concrete per eight-hour shift, which is enough to build a single-story house with a footprint of just under 50 m². Due to the construction-relevant physical properties of the material, a solid subsurface is the only requirement for a building project. Special foundation strips made from the same material form the foundations for the first bricks and also mark out the floor plan of the building. Further special components in the Modular Assembly System (MAS) make it easy to incorporate windows and doors.

Effective protection from the elements

The virtually seamless, interconnecting system offers very good protection from the elements on its own. However, in areas where the local climate requires, the cavities of the individual basic elements can be filled with additional insulating material. The polymer concrete is also frost-proof, as it does not absorb water. What’s more, it exhibits excellent resistance to abrasion and is not susceptible to major temperature fluctuations. It does not need to be plastered, painted or tiled, but can be, if required, and the completed houses also satisfy the quality requirements of European building standards.

Another important property of the corrosion-resistant polymer concrete is how resistant it is to external influences from aggressive waste water and mineral oils, which is particularly important in regions with poor infrastructure. The houses can also withstand the influence of acids, alkalis, fumes and gases without sustaining any damage. At the same time, the polymer concrete itself does not react with the environment. If buildings have only been required on a temporary basis and the blocks are no longer needed, they can be mechanically destroyed with ease and then recycled.

Pilot project in a future market

However, these are not the only properties that are important for the widespread success of the project. Given the often limited financial resources of governments and aid workers on the ground, and the large volume of housing that is required, it is important that buildings can be put up fast and at low cost. The benchmark in this respect is a sample house that has been built behind Polycare’s head office. It took two people less than 12 hours to construct the single-storey building, which boasts 37 m² of living space. Material costs came in at less than 3000 euros.

Polycare passed an initial endurance test during a presentation in Namibia. The southern African country has long-term plans to build 200,000 affordable homes to improve the quality of life for large sections of the population on a sustainable basis. A study is now being carried out to clarify how an initial model settlement based on the German technology could be financed.

Want to stay up to date on innovative engineering? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

How cleanroom technology is supporting one of today’s most important research projects. 

Deep below the Earth’s surface, research history will soon be made. The European XFEL, a research project worth a ten-figure sum and headed by the DESY (Deutsches Elektronen-Synchrotron) research centre, will start operating before the end of the year. A high-power X-ray laser forms the hub of a tunnel system with a total length of 3.4 kilometres that extends from a district of Hamburg to the edge of Schenefeld in Schleswig-Holstein. It will offer unprecedented insights into the nano world. A total of 11 European countries are involved in the project, with Germany assuming around 60 percent of the costs. 

Particle accelerator in Hamburg

Superlatives should generally be used sparingly, but the European XFEL research installation is genuinely a project of huge dimensions. Costing 1.22 billion euros, it produces 27,000 X-ray laser flashes per minute – a billion-fold increase compared with conventional X-ray radiation sources. This makes it possible to capture images of extremely rapid processes. 

The European XFEL centres around a superconducting linear accelerator 1.7 km long. The electrons are accelerated in a vacuum in 96 tube modules, each 12 metres long. The process of joining together the separate modules was extremely complex due to the technology they contain and the interconnected measuring systems. Everything also needed to be kept meticulously clean. Assembly work had to be performed under cleanroom conditions because any particles would significantly disturb the vacuum in the beamline tube. 

Versatile, mobile and cleanroom-compatible 

The assembly solution that had to be created also needed to be mobile because anything else would simply have been uneconomical. After all, this work had to be performed throughout the tunnel system. This is where CCI – von Kahlden GmbH came into its own. The cleanroom specialists from Leinfelden-Echterdingen built three mobile cleanrooms. CEO Thomas von Kahlden has been using our profile technology for over eight years. Given the specific requirement for clean processes and closed grooves, Profile X 8 was used for this project, too.  

Cleanroom-compliant assembly and maintenance for the European XFEL 

A basic platform from item forms the basis of the mobile cleanrooms. The platform has “hoods” that are pressed against the module connections on the right and left, with the beamline tube as the core. Ventilation technology with appropriate filtration creates a clean environment within minutes of the system being switched on. Staff then simply need to wear long gloves to extend their hands into the cleanroom area and carry out the assembly work. The ventilation technology creates an overpressure within the system. This means air flows against the openings where personnel reach through to carry out their work and ensures that no external impurities can get into the system. 

Even now that the linear accelerator has been taken into service, the mobile cleanrooms are still in great demand. Thanks to our lifting feet, they can adapt flexibly to uneven surfaces in the tunnel and are vitally important for servicing and maintenance work on the module connections. The necessary tools and connecting elements are first inserted at the lower level of the system and cleaned. Once the member of staff has taken up his position, he can lift the parts to the correct working height via a linear axis. 

Do you want to be kept up to date on innovative research projects? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

How Irmler GmbH is breathing new life into the record pressing market.

Good old vinyl has been enjoying a global renaissance for a number of years now. By the end of 2016, vinyl sales were nearly another 50 percent up on the previous year. Since the 1980s, the emergence of CDs followed by MP3s and online streaming has resulted in the music market moving increasingly towards non-physical consumer items, but vinyl is bucking this trend through its format alone.

Modernising old record presses

There are, however, far fewer vinyl presses in working order to meet the ever-increasing demand for record production capacity. In 2014, Irmler GmbH was therefore asked to use modern-day technology to breathe new life into an old record press. The retrofit of the existing system based on technology established for decades was a big success. During the project, it became clear that the core process could be made far more efficient by using the latest guidelines and processes.

There are no longer any vinyl record press manufacturers anywhere in the world, though, so the retrofit customer asked specialist mechanical engineering company Irmler about the feasibility of planning and building a completely new press. The supply of spare parts for the old Alpha Toolex machines was to continue independently in parallel to this.

Using modern-day technology to make records 

A 3D drawing of the modernised system served as a basis. This was combined with a cutting-edge control system and servo technology using CAD. The core process – pressing the record – still works in the same way as it did 50 years ago. New valve technology uses hot/cold media to control the temperature of the moulds while they are pressed together under high hydraulic pressure.

A project period was defined jointly and the basic operation of the machine, including the entire hydraulic system, was tested at Irmler. The fully assembled system was only put to the test after it had been installed at the customer’s premises. Since a large amount of peripheral equipment is required to press vinyl records, it was impossible to perform a test run in the construction workshop at Irmler GmbH. 

Automation from extrusion to packaging

Some of the key benefits of the new record press lie in the servo technology between pressing and the packaged record. The extrusion process was completely revised with heating cycles controlled electronically using a PLC and state-of-the-art drive technology. All peripherals also benefit from PLC control and can now be adjusted more flexibly than with the manual control system previously used. Completely free configuration of counters and times is also possible via a touch panel. The feeding in of pucks and labels has been optimised, while the processes of inserting cooling plates and packing in paper sleeves have been automated.

Safety and quality assurance activities have also been revised for the prototype. State-of-the-art safety based on the Machinery Directive is now assured, while monitoring the position of the pressing frame and the hydraulic pressure ensures consistently high product quality.

Record presses from Irmler

Once the prototype had been installed and operated for a few months, it quickly became clear that the machine satisfies the calculated performance data and produces records of the quality expected by the customer. Further orders followed as a result. 

The customer now has no fewer than five new record presses for vinyl production. The quality of the sound carriers is just as high as on the old machines. The control system’s comprehensive documentation and error identification minimise troubleshooting time in the event of a fault.

Do you want to stay up to date with the latest developments in specialist mechanical engineering? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

With the holidays fast approaching, it’s a good time to take a look back at the year’s most popular articles. Our blog will also be taking a short break for winter. 

During 2016, item once again invested a lot of time and effort in improving and expanding its customer care services. Besides a major project that we’ll be presenting in detail after the winter break, one of the most high-profile elements in this expansion was the launch of item Hannover. In this interview about the new site, head of sales Robert Kubat introduces himself, his team and the ambitious goals for customer care in the busy urban region around Hannover, Braunschweig, Hildesheim and Wolfsburg.

Shanghai Tower: The secret to its stability

item was also scaling new heights in spring. Our tried-and-tested aluminium profile technology played a small but important part in the construction of the world’s second-tallest building. Profiles from the MB Building Kit System have been used to create a large frame to hold numerous copper plates in place on the 125th floor of the Shanghai Tower. These plates are part of the permanent magnet structure that exerts a braking effect on the 1000 metric ton tuned mass damper weight. The damper weight itself is a crucial safety element for counteracting the enormous forces that act on the sky scraper during earthquakes and storms. 

Applying lean production in logistics

Another favourite topic in 2016 was our lean-production duo of just-in-time and just-in-sequence, both of which focus on optimised logistics procedures. Just-in-time deals specifically with the conditions, advantages and risks of a needs-synchronised production system that operates with dramatically reduced material stock levels. While a just-in-time approach dictates that materials are only requested and supplied when they are actually needed, just-in-sequence expands this system to include the order in which the materials are supplied. For example, the materials needed in a production system are delivered as and when required and in the exact order in which they are installed. This two-pronged approach can be particularly beneficial when manufacturing products for further processing.

From Karakuri Kaizen to linear technology

In November, the item blog article entitled “Automation with smarts” trained the spotlight on Karakuri Kaizen. The short excursion into the historical origins of purely mechanical automation was not the only well-received aspect of this piece. The blog article also shows how Karakuri Kaizen – known also as low-cost automation – can help integrate the lean philosophy into a state-of-the-art production environment in four steps. Another popular article that specifically addressed automation was our overview of linear technology. Besides covering the fundamentals of the technology, this article also provides a practical comparison of guides and drive technologies for various application scenarios.

Creative and committed with item

Our customers were also introduced to a whole range of creative ways that item profile technology can be used to put projects into practice. Among the most striking examples this year were the smallest car wash in the world and even a complete car. The design department at item and the trade fair team gave us a peek behind the scenes in 2016, too. What’s more, there was a great deal of commitment in evidence elsewhere in the item world. For example, one of our employees in China is growing fruit and veg in front of one of our sites. In the true spirit of Christmas, he regularly shares his harvest with his colleagues. The support programme for disadvantaged young people run by our South African partner Directech is also bearing fruit.

We hope you’ve enjoyed the item blog this year and its content about our products, projects and people. We’d like to wish all our readers, customers and partners a very happy festive break and a great start to the new year! We’ll be back after the holidays, with the first article for 2017 on 11 January.

It happens all the time – a term becomes so well established that nobody bothers to explain what it means any more. Most people assume everyone knows what automation is. But is it really so self-explanatory? As we all know, it never hurts to take a closer look at something, so we’ve put together a few interesting points about automation. The following article looks at the etymology of the word, technical milestones throughout history and the latest innovations in linear technology. 

1. Automation is a genuine classic 

Since antiquity, mankind has been grappling with the question of how to automate processes. The ancient Greek word Automatia translates as “coming from itself” or “self-moving”. The engineer Heron of Alexandria was a pioneer in the early days of automation. Also referred to as “Mechanicus”, he earned his fame as an inventor thanks to a door-opening mechanism he designed for an Alexandrian temple. While awestruck believers were convinced they were witnessing the power of the gods, it was actually an ingenious, but very human, talent at work. 

Heron’s ideas about automation have certainly stood the test of time. Alongside the temple in question was a container that was half-filled with water located under an altar fire. The heat of the fire caused the air in the container to expand, forcing water through a hose and into a second container that was connected to the doors via rollers and chains. The heavier the second container became, the lower it sank and the wider the doors opened. By contrast, extinguishing the altar fire generated a vacuum that drew the water back into the first container, thereby closing the doors.    

2. Automation really takes off in the modern era 

Although the Greeks were the first to invent automation, they never used it specifically to make work easier. Aristotle’s desire for a tool that “could complete its work on command, or even without having to be told,” was not satisfied. It was only in the 18th century that the next milestones in automation followed. The first of these was achieved by Edmund Lee in 1745, when he designed a structure that allowed wind mills to turn completely autonomously. Previously, wind mills had to be turned into the wind by hand, but now the fantail ensured that the mill could align itself independently. 

All the same, it was an invention by another Englishman that proved truly historic. In 1784, Edmund Cartwright invented the power loom – the first steam-powered weaving machine in history. The steam engine itself ushered in a genuine revolution in industrial production. From now on, the physical strength of people and animals was no longer a limiting factor. Thanks to automation, goods could be manufactured that would have previously seemed unimaginable. The production line was added into the equation during the second industrial revolution, while programmable logic controllers (PLCs) brought about the third revolution. 

3. Computers help automation move one step further forward 

The current evolutionary stage in automation – Industry 4.0 – is another remarkable milestone in the development of a basic idea that reaches back to the very origins of European civilisation. However, Industry 4.0 also marks a significant change of focus. While it was the individual machines that took centre stage in the past, it is now the way these machines are networked that matters more than anything else. Thanks to intelligent data processing and transmission, customised products can now be manufactured with the same cost advantages usually associated with mechanical series production. 

The benefits of cutting-edge automation software are not solely to be found in spectacular robots. A good example of state-of-the-art solutions for industrial automation is linear technology. There is now intelligent linear technology software that lightens the workload of human users. Based on a small number of details, the software configures a custom linear solution. However, software support isn’t limited to selecting and configuring parts – another program offers superlative support for commissioning systems.

Want to keep up to date on what is happening in the world of automation and linear technology? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

The third of December saw the topic of disabilities pushed to the very top of the global agenda. 

Around one billion people have some form of disability. Although equality and the absence of barriers should be universal standards, these goals have yet to be achieved. Each year, on 3 December, the International Day of Persons with Disabilities is celebrated as a way to raise awareness of the situations faced by those affected. Information events, panel discussions and exhibitions help to clarify issues and turn the spotlight on how persons with disabilities are currently treated. For example, the huge potential they offer the labour market is often overlooked.  

Day of reflection and action 

The first International Day of Persons with Disabilities was held in 1993. The United Nations had instigated the event in October of the previous year, as the culmination and continuation of the Decade of Disabled Persons, which ran from 1983 to 1993. The aim is to ensure that disability is accorded the attention that it deserves. On this day, all around the world, attention is focused on crucial issues such as how the rights of persons with disabilities are respected nationally and whether barriers really are being broken down. 

The theme for this year’s International Day of Persons with Disabilities is “Achieving 17 Goals for the Future We Want”. This relates to the ambitious 17-point UN programme that has been conceived with the aim of making the idea of a better world a reality. One key requirement of this programme relates to tackling discrimination in all its forms. And there is good reason to celebrate in 2016 – the “Convention on the Rights of Persons with Disabilities” has been in force for ten years. Now is the right time to reflect on what has been achieved so far. It took five years to draw up the ground-breaking document, which has been ratified by 167 countries. 

Barrier-free workplaces 

The facts speak for themselves. Persons with disabilities often have excellent qualifications – and yet are very easily overlooked on the labour market. For example, a higher proportion of unemployed people with severe disabilities are specialists in their field than is the case among able-bodied unemployed. A lot of potential is going untapped. If this potential were to be harnessed, companies would not just gain access to highly motivated and qualified workers, they would also make real progress in tackling the shortage of skilled workers.

A barrier-free work bench has proven ideal as a means of integrating employees with disabilities into industrial production. A work bench like this can be adapted to suit the physical characteristics of employees and also takes into account a whole range of additional factors. One important consideration is the handling area, which is significantly smaller for wheelchair users and people who have difficulties walking or standing. What’s more, there are government integration bodies and numerous state funds that offer companies advice, practical support and even financial aid. 

In the era of Industry 4.0, automation is becoming increasingly important. However, the term “automation” covers much more than just the complex high-tech robots that many associate with modern industry. The principle of Karakuri Kaizen, a central component of the lean philosophy, centres on easily implemented automation solutions that operate on a purely mechanical basis. By making clever use of kinetic energy as it is released and consistently avoiding waste, this approach can yield striking results. 

The origins of Karakuri Kaizen 

To understand the roots of Karakuri Kaizen, you need to go back in time to 19th century Japan. Karakuri ningyō translates roughly as “mechanical doll”, which is meant in the literal sense. At the time, small machines were very popular. The same was true in Germany (consider the works of the German romanticist E. T. A. Hoffmann, particularly the “Sandmann”, for example), although there was significantly more enthusiasm for mechanical dolls in Japan. Three categories of Karakuri emerged: Zashiki karakuri (“reception room dolls”) were used in the home, while Dashi karakuri (“festival cart dolls”) were used during religious festivals and Butai karakuri (“theatre dolls”) took to the stage. 

The most famous type of karakuri doll by far is that used as a tea server. These dolls travel a pre-determined distance, their white feet elegantly swinging to and fro. All the while, their head bows, offering their human counterpart a cup of tea. When the tea is taken, the Karakuri stops. Once the empty cup is put back, the diminutive server turns around and returns to where it started. It is the doll’s two hands that serve to trigger movement. The presence or absence of a load intitiates a chain reaction that ultimately transfers motion to all the moving parts of the doll.  

Becoming more effective with Karakuri Kaizen 

Of course, the main purpose of the above example is to entertain, but it does highlight the key relevance of Karakuri Kaizen for industry – that simple means can be used to achieve an automatic movement that rather than wasting energy uses it directly for a useful purpose. In this respect, Karakuri Kaizen is closely intertwined with the types of waste covered by the 7 Muda, which are to be avoided. The following Karakuri Kaizen rules have emerged: 

• Ensure objects are always moved by means of mechanical energy, without any pneumatic, electric or hydraulic drives.
• Spend little money and utilise constructions that are easy to maintain.  
• Make creative use of existing energy and interconnect different Karakuri Kaizen systems. 
• Also make use of your employees’ creativity and encourage them to share their experience. 

If Karakuri Kaizen is to work, all these rules need to be firmly anchored throughout the company. Kaizen, the philosophy of striving to change for the better, is crucial in this respect. The current state of affairs is only ever one stage on the path towards continuous improvement. 

Low-cost automation 

But how exactly do you put this rather abstract concept into practice? It all starts to take shape when you look at low-cost automation (LCA). At item, we consider LCA and Karakuri to be much the same. Neither use pneumatic, electric or hydraulic drives, instead relying on purely mechanical energy – such as gravity and spring force – to move workpieces, workpiece carriers and load carriers (to name but a few examples). In the Japanese automotive sector, there are even special LCA training centres, known as karakuri dosho. These centres offer intensive courses to help workers and engineers really grasp the concept of Karakuri and incorporate it into their work.  

The following steps should be followed when rolling out low-cost automation: 

1. Improve manual handling work (e.g. forwarding workpieces to other workstations via roller conveyors).  
2. Separate manual and machine work.  
3. Install technical solutions that are simple, efficient and low in cost. 
4. Only now should you consider installing more complex technical solutions.  

Industry 4.0 is the talk of the town in Germany. However, it’s all too easy to lose sight of what the fourth industrial revolution means for ergonomics in the workplace. The fact these two issues are closely intertwined is difficult to dismiss. After all, Industry 4.0 is running rampant while the German population is shrinking and getting ever older. Companies are increasingly looking at how they can keep their employees fit for work – just as much as they are exploring the application of digital systems. The following blog post turns the spotlight onto the direct consequences of the digital revolution for health at the industrial work bench. 

Work bench ergonomics through human-machine collaboration 

Last time, we looked at cyber-physical systems (CPS), with workpieces being represented by a software agent and therefore able to communicate with each other. Of course, that doesn’t mean people are left out in the cold by this Internet of Things. Instead, their involvement can extend far beyond simply operating controls. People will themselves become part of the network – and all in line with ergonomic principles. Let’s imagine that product A has been tasked with deciding who should machine it. It will review the personnel data at its disposal (such as height or previous jobs) and determine that person B is the most suitable. Person C is not selected because there is a risk the machining operation will put too much strain on him or her. 

Another way that people and machines will interact with each other as part of Industry 4.0 is in the use of collaborative robots. In this case, people will, to a certain extent, work hand-in-hand with their artificial colleagues. This division of labour has a lot going for it in terms of ergonomic considerations. Firstly, the machines can take care of tasks that would quickly result in physical strain for human workers due to awkward postures or heavy tools, for example. Secondly, the latest generation of robots have edge-free outer skins, which means they can work directly next to people. As a result, protective guards and special work clothing are no longer required. What’s more, the robots use special sensors to detect contact and take careful evasive action.  

Ergonomic work bench for manual work 

It’s safe to say that people are not being pushed into the background. Manual production is still hugely important for Industry 4.0. Although work like this is well known for being physically demanding, the ever greater integration of workers into digital systems also means there is a growing level of transparency regarding ergonomics in the workplace. If key data (height, ideal handling area, etc.) is available for all workers, companies can ultimately ensure their staff are deployed in as efficient and ergonomic a way as possible. In the future, there will be no excuse for not using steplessly adjustable, ergonomic work benches. That is why Industry 4.0 represents another step forward in the development of ergonomic work bench design. 

Another remarkable emerging trend in ergonomic working practices relates to “wearables”. Although most people will automatically think of smartwatches, wearable computer systems also offer a whole host of benefits for the industrial work bench. For example, there are already intelligent gloves that actively help wearers by indicating whether individual production steps have been completed properly. Meanwhile, an integrated scanner ensures that goods can be identified in next to no time. Tools like these help workers to complete several tasks at once – without having to perform any additional movements. All in all, it’s exciting to think what else the future could bring for ergonomics at the work bench. 

Do you want to stay up-to-date with the latest trends in specialist mechanical engineering? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

Following on from our detours to South Africa and Mexico we’re continuing our breathtaking trip through the world (of item) with a return journey to China. Since we’ve already reported from the People’s Republic about the Shanghai Tower and the homegrown veg of our colleague Mr. Sun, it’s high time we focused on the business activities of item in China. Indeed, the company only recently staged a special competition and showed what it can do at one of the country’s biggest industrial trade fairs, the Industrial Automation Show (IAS). 

A fun way to discover the benefits of lean production 

The People’s Republic is the most important export market for German mechanical engineering and accounts for a volume of around 17 billion euros. item has been active in China since 2010 and is championing lean production in the country. After all, our Chinese counterparts also understand how important it is to boost efficiency and optimise production.  

We recently demonstrated the benefits of our lean Profile Tube System D30 in a small competition in Qingdao. The assorted teams had to assemble three transport trolleys using the same drawing – and do so fast. They were able to use Profile Tube System D30, a combination of D30 and the MB Building Kit System and the steel tube system of a competitor. The winning team quickly realised the benefits of D30 and were therefore the first to assemble a usable trolley. 

Lots to see at the Industrial Automation Show 

Early November saw the Industrial Automation Show (IAS) take place in Shanghai. Staged at the National Exhibition and Convention Centre, it is one of the biggest industrial trade fairs in China. Each year since 2003, the fair has played host to countless exhibitors, predominantly companies from the process and production automation sectors, although robotics, electrical plants and IT solutions also play an important part. It is fair to say that IAS is the place to show Chinese businesses what innovative specialist mechanical engineering solutions can do. This year, from 1 to 5 November, more than 600 exhibitors from around the world set out their product highlights on an exhibition area measuring 55,000 square metres. 

Other than a break in 2015, when the trade fair moved to a new venue, we have been a regular exhibitor at IAS since 2012 and it is certainly our most important trade fair in China. It is the ideal place to make highly promising contacts. In general, trade fairs are much bigger events in Asia than they are in Europe. Before you know it, a cluster of people will form around you – and the expectations are high. In any case, our profile and linear technology and a Karakuri exhibit featuring our Profile Tube System D30 proved very popular with visitors. Our live demonstration of the MB Building Kit System was particularly well received and was even drawing a lot of attention during the set-up phase.

Customers in the German region around Hanover, Braunschweig, Hildesheim and Wolfsburg can now rely on first-hand local support from item. Based centrally in Isernhagen (Imkerstrasse 3), near Hanover, the new branch delivers all the convenient benefits of local support. As the new team gets down to work, we couldn’t pass up the opportunity to quiz head of sales Robert Kubat about item Hanover.  

What immediate benefits does the new Hanover site offer existing and prospective customers?

Having us close by is a huge plus point for customers in the region when it comes to all the various aspects of the service that item provides. Customers can come to us to get expert advice fast, or we can go to them. We’re already working with our customers and partners to provide training in how best to use the benefits offered by item components and we’ll be creating and offering more interesting training courses and workshops over the coming years. The immediate advantages that we are offering our customers include access to a comprehensive storage facility and the option of having a broad range of projects engineered and built here in Hanover.

What is changing for you?

We have a lot more space for building and presenting custom solutions here at the new item site in Hanover. Our close proximity to customers also makes it easier for us to quickly identify their needs, suggest solutions and then put them into practice just as fast.

What would you say are the defining characteristics of the region around Hanover?

Hanover is particularly important for industry and the closely associated logistics sector. The comparative closeness to item headquarters in Solingen and neighbouring item sites in Mühlhausen, Hamburg and Berlin is also really paying off. We are improving our response times and that makes us better prepared for the many challenges in our sector. What’s more, Hanover is a major player among the trade-fair cities in Germany, Europe and the world. That is very clearly reflected in the outstanding infrastructure.

What kind of capacities – in terms of space and personnel – does the branch have?

We’re already using our training room, which measures approx. 70 m², and our exhibition room, which also measures around 70 m². Altogether, we have a total area of 3,100 m² at our disposal, some 2,500 m² of which is being used for logistics and production operations. The permanent team at item Hanover numbers 13 members of staff. However, the new facilities give us room to grow. We are confident that we’ll be further expanding our capacities at item Hanover in the next few years.

What kind of projects can you put into practice directly on site?

We can make virtually any project a reality here in Hanover, from the smallest frame to a complete production line. It doesn’t matter if it’s a sketch for a project idea or putting that idea into practice: Whether simply cutting a profile to size, configuring a construction kit or providing a fully assembled custom solution – our on-site team is perfectly equipped to meet all needs.

Will all types of training be offered, or just training in certain areas? 

When it comes to training, workshops and courses, we’ll be taking our lead from the usual quality standards that other item sites deliver. As a full-service site, item Hanover will extend our training portfolio. Our coaches will be adapting courses such as our basic training courses to meet customers’ needs. In the future, there will also be a stronger focus on state-of-the-art lean production methods. Our lean partners and experts in Hanover will be working hard to make this crucial subject matter more accessible to our customers. We’re also happy to put together project-specific training content that we can then coordinate with customers and other interested parties.

Are there plans for company open days or other events? 

We will certainly make sure item Hanover has a suitable opening event. In-house trade fairs are always an ideal platform for communicating with customers on a level playing field. We’re looking forward to opening our doors and showcasing the new opportunities that the new site offers the Hanover region and surrounding industries.  

What is likely to be the most interesting challenge?  

item Hanover will help us really develop our base in the region, thereby enabling us to generate new contacts and implement new projects in a shorter space of time. That will be an interesting task for our team and we’re already looking forward to taking it on.

Is there one particular aspect of your work that is especially important to you?

We will only be able to achieve our goals by working as a team. item has always understood the importance of taking employees with different strengths and bringing them together to form a strong “home team”.

When many of us think about Mexico, the first things that spring to mind are usually tourist-trail stereotypes – huge sombreros, lively Mariachi music, Aztec temples, scorching heat and cacti that cast long shadows. It’s all-too easy to overlook the strong economic recovery that the country with the world’s largest Spanish-speaking population has experienced in recent years. During that recovery, particularly close ties have been forged with Germany in what has emerged as a mutually successful cooperation – and item has played a part in that. A great deal is also being done to promote bilateral cultural exchange.  

 A tried-and-tested partnership 

“If there were just one part of this Earth that you could call paradise, it would have to be Mexico.” Those were the words that explorer Alexander von Humboldt used to sum up his experience of Mexico in the early 19th century. The legendary naturalist is the founding father of German-Mexican relations. However, those relations only really started to intensify in the year 2000, not least thanks to a free trade agreement between Mexico and the EU. While there were only 600 German-headquartered companies in Mexico in 2002, today there are 1750 operating in the country. Together, they employ more than 120,000 people and account for just under seven percent of Mexico’s gross domestic product. 

Germany has become the country’s biggest EU trading partner. Mexico’s geographical situation between North and South America and its independence from the euro are both important factors, as are business-friendly trade deals, particularly with the US. However, Mexico is also an interesting sales market in its own right. For example, German exports last year hit a total volume of 11.1 billion euros. A large number of the German companies with branches in Mexico operate in the automotive sector, although the country’s chemical, pharmaceutical and mechanical engineering sectors are also strong. 

Success in Mexico 

Given these highly promising developments, it is no surprise that we are also represented in Mexico – and have been for almost two years. The original idea was to have a central warehouse for two of our US distribution partners, so that they could be supplied with materials efficiently. In 2011, during the course of an expansion plan, the warehouse became our headquarters for North and South America. In 2014, after a few more than encouraging years, we took the decision to build up strong support from distribution partners.  

We now have four distribution partners in Mexico – item Noreste Mexico, item Oeste, item Sur Mexico and item Bajio. The latter is the latest company to join the item network in Mexico. The Bajio region includes the states of Aguascalientes, Guanajuato, Jalisco, Queretaro and San Luis Potosi and has become the central hub of Mexico’s automotive industry. The electronics and aerospace sectors are also booming there. All in all, it offers the best conditions for adding another successful chapter to the history of German-Mexican trade relations. 

Germany-Mexico Year

One of the latest developments in the exceptionally good relations between the two countries is Germany-Mexico Year, which kicked off in April 2016 and will run until May 2017. It forms part of the agreements made by the Binational Commission (BNC) of Germany and Mexico, which was established in 2015. The aim is to showcase culture, economy, science and politics in the partner country. 

The launch event in spring – staged at the Martin-Gropius-Bau exhibition hall in Berlin – was an exhibition entitled “The Maya – Language of Beauty”, which was opened by Germany’s President Joachim Gauck and Mexico’s President Enrique Peña Nieto. A major exhibition of paintings by Otto Dix (1891-1969) followed in Mexico in June. Future highlights of the “Año Dual” include the Max Planck Science Tunnel and an open-source project about urban mobility. 

Want to keep up to date on what’s going on in the world of item? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right! 

In the past, we have often reported on the unusual constructions that can be achieved using our profiles.

These include a juice bar on wheels, real competition for legendary oracle Paul the Octopus or the complete fittings for a chic fashion boutique. In this section we have a few more ideas. Alongside two original hobby applications from Germany and Switzerland, there is also a present for our partners at item North America to mark 20 years of the company. 

Perfect roofing for tomatoes  

Protective roofing can make all the difference for plants. Hobby gardeners know that it takes more than green fingers to protect their plants from inclement weather such as hail or heavy rain. One of our colleagues grows tomatoes in his spare time, and relies on a tomato roof to help him. He has previously used versions made of wood and Multi-wall Sheet panels. 

There was, however, one big problem – this rather rigid construction was not easy to take apart in the autumn, so took up a lot of space while being stored for the winter. Thanks to our Profile Tube System D30, our colleague’s new tomato roof is as flexible as it is stable. Two Multi-wall Sheet panels 8 mm, which are usually used as partitions or flooring beneath a roller conveyor, form the actual roof and provide perfect protection for the tomatoes.  

Whatever the weather 

It’s a well-known fact that smoking is bad for the health. However, it is up to each individual to decide what is best for their health, as long as it doesn’t affect anyone else. This is particularly true at home. We have received pictures of a smoking room from Switzerland. The Swiss call it a “fumoir” (from the French “fumer” – to smoke), which really sounds much more elegant. 

Since the Swiss DIY enthusiast has a house with no balcony, he simply built his own shelter against bad weather. This means he can indulge his vice at home whatever the weather, without polluting the indoor air. The construction is based on our Profiles 8, securely connected using Automatic-Fastening Set 8. The panels are attached on all sides and secured precisely with several Panel-Clamping Strips 8. And the Door Stop Seals 8 have shown they not only protect housings for production processes, but are also ideal for small smoking areas. 

Rallies in the lunch hour 

There’s always time for a bit of fun – a positive approach is key for a friendly and productive working environment. And what could be better for team-building than a bit of sport in the lunch hour? This is certainly what our American colleagues thought! Based a tried-and-tested construction from the staff at item West, we got together with item Mid Atlantic in Solingen to build a table-tennis table. This is to be a joint present to mark the 20th anniversary of item North America. This enables the Line X cleanroom profiles to show off their additional “fun factor” qualities.

With each new generation of vehicle, engineers are not only extending the driving range, but also seizing the opportunity to test out networked driver assistance and safety systems. However, there are comparatively few drivers who benefit from this progress in their everyday lives. The reason for that is simple – electric cars are expensive.

That is why Brazilian-born engineer Paulo Camasmie, who lives in the USA, has been enthusiastically working on developing his very own model of vehicle. He believes it is unethical that not all cars today come with state-of-the-art safety technology, such as collision warning systems, and that effective protection is therefore reserved for the wealthy. Fundamentally, there isn’t actually anything new about the Atticus robotic car – and that is precisely what makes it so innovative. The vehicle could be compared to the development of the iPhone – it uses existing technology and optimises it.

More than autonomous driving  

It is the best kind of impassioned side project. Paulo has been running a successful trike company called Catrike for 16 years and is therefore not financially dependent on his electric car project. In his free time, he can tinker away in his garage to his heart’s content and without any pressure. To build the vehicle’s frame, he has opted for our MB Building Kit System and Profile Tube System D30. He came across both while carrying out research at a trade fair. In fact, our profile technology made such a lasting impression on him that he now uses it, not just for the Atticus robotic car, but for building new trikes, too. He is particularly fond of the modular character of the item portfolio and has as yet never come across a situation where something won’t fit. 

Paulo doesn’t think much of semi-autonomous electric cars, where human drivers still need to intervene when things get difficult. Instead, he focuses on the driving experience, when human drivers are in full control and state-of-the-art technology protects vehicle occupants. Thanks to its modular design, the Atticus robotic car can easily be fitted with new safety systems such as V2V (vehicle-to-vehicle, when cars communicate with each other) and V2I (vehicle-to-infrastructure, when signals from traffic lights are forwarded). 

Safety should not be an exclusive privilege 

Although Atticus is still just a prototype without an outer shell or safety aids, Paulo has one set goal in mind. He wants his vehicle to open up the electric car concept for the mass market and ensure that maximum safety on the roads is not an option reserved for buyers with fat wallets. If everything goes to plan, and the necessary partners can be found, he should finally get there by 2020. A deeply personal experience lies at the root of Paulo’s worthy vision – his sister Simone was involved in a traffic accident in Brazil in 1984 and spent a month in a coma. 

But where does the name “Atticus” actually come from? Well, the innovative vehicle has Paulo’s daughter to thank for that, as the name comes from Harper Lee’s all-time classic “To Kill a Mockingbird” (1960), which she was reading at school. In the book, which is set in the 1930s, Atticus Finch is a courageous lawyer in the southern United States who defends an innocent black man. The character quickly became a symbolic figure for ethical behaviour and progressiveness. Paulo’s daughter was reminded of her father and immediately recommended the inspirational book to him. Naturally, he was very moved that his daughter saw him in such a positive light and thus he had the perfect name for his car. 

Do you want to stay up to date on the latest, innovative ways that item products can be used? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

How the up-and-coming talent from our South African partner made a big impression at one of Africa’s biggest trade fairs. 

A little while ago, we introduced you to our South African distribution partner Directech. Through its internship programme, it offers young people from the local area a wide range of opportunities to develop their skills and gain valuable professional experience. Now we’re pleased to report on more great news from our South African partners. Our friends from Johannesburg had the chance to show what they can do and make lots of contacts at this year’s Electra Mining (12 to 16 September), which is one of the biggest industrial trade shows in Africa.   

A trade fair stand with a high profile  

Bottle openers and sunflowers   

It was 23 September and the big day had arrived – up-and-coming artists were eager to find out which painters had won the item Art Prize.

Our branch in Ulm regularly hands out awards to promising talented young artists from the German painting scene. All conceivable painting techniques are allowed, the only condition is that the work is related to the chosen theme. This year’s theme was “Unlimited possibilities”, which reflects the modular nature of our components on the one hand and gives the artists the greatest possible freedom on the other. “Ich kann nicht” (I can not ), a self-portrait by Kerstin Kraus, won first prize in two out of three categories. The panel of judges, comprising the 30 nominees for the competition, put the work in first place with a clear lead and the public attending the preview also preferred this piece. The winner of the “item Staff Award” category is Ana Lena Sprandel, who studied free arts at the University of the Arts Bremen and submitted a painting titled “Girl Painting”. However, our love of the arts extends far beyond this competition.

A quarter century of supporting art

It was item employee Konrad Mock who first nurtured the company’s commitment to promoting the arts. With a background as a trained art historian, he had previously run a gallery and therefore had excellent contacts in the art world. When he was asked in 1991 to organise the opening ceremony for our Ulm site, he turned it into a small but perfectly formed art event that was extremely well received by the guests. He demonstrated such outstanding organisational skills that he was promptly appointed as head of logistics for the site. However, his passion for the arts has not suffered at all, and he continues to play a leading role in all our art activities, which slot seamlessly into the cultural, charitable and sports sponsorship endeavours at item. 

Thanks to his excellent connections, Mock was able to stage repeated individual and group exhibitions. “There is a close link between art and technology. Besides that, art is a perfect fit for item. Outstanding product quality is hugely important to us, particularly when it comes to aesthetics. What’s more, the public and operational spaces here are always very clean and offer an amazing venue for showcasing art,” emphasises Mock. In 2002, the exhibitions were replaced by the Art Prize programme. After the prize-giving ceremony, all the works can be viewed at the Ulm branch for around 12 weeks and anyone interested can also purchase them commission-free. However, the prize-winning paintings go straight into the impressive item art collection, which is constantly growing with new acquisitions.  

Works of art at all sites 

When a work of art is added to the item collection, it isn’t hidden away in some vault somewhere, it is circulated through our branches as a concrete expression of our passion for aesthetics and an extra element to enrich the working environment. Often, members of staff will be irresistibly drawn to a particular painting in the gallery website and can find out whether it can be made available to their site. Visitors to the product exhibition in Ulm also enjoy dipping their toes into the world of the arts as an added extra. As far as Mock is concerned, there is no end in sight for the love affair between engineering and painting: “When the Art Prize is announced, we always get a large number of submissions, because we’ve built ourselves a certain reputation. In the last two years, we also attracted an audience of more than 500, which is remarkable.”

Do you want to stay up to date on everything item is doing around the world? It couldn’t be easier – simply subscribe to the item blog by completing the box at the top right!

China is well known for its diverse cuisine, and sitting down to a meal together is an important part of Chinese culture. However, China’s astonishing growth since the start of the new Millennium has had a huge impact on food supplies. For many people in China, the traditional approach of getting supplies from local farmers has given way to a reliance on industrially processed foods. In the large cities, direct contact with producers has been replaced by the anonymity of the supermarket. At the same time, the demand for food has grown as people have become wealthier. 

Industrialised food supplies

Over the years, as it struggled to adapt to new challenges, the food industry in China became a centre of focus. With no efficient national food safety controls, companies would often do anything and everything they could simply to maximise production output. One of the most serious examples of this was the Chinese milk scandal, when baby food produced using contaminated ingredients resulted in hundreds of thousands of infants developing serious illnesses. Six babies died as a direct result of contaminated baby food. The consequences could be felt as far away as Europe, as young parents exploited a grey market to import huge quantities of safe baby food from the EU – and ideally products that carried the “Made in Germany” label.

Getting back to basics

Mr. Sun, one of the quality management officers at the item site in Qingdao, China, was well acquainted with these fundamental food supply problems. It also happened that there was an area in front of the item plant that was disused and covered in undergrowth that reached as tall as a man – and the passionate gardener soon joined the dots: Why not do something to take back control of food supplies?

After a brief discussion with the management team, it became clear that item was more than happy to support this sustainable idea. In his lunch breaks and at weekends, Sun started work to cultivate his produce. He was able to make use of the site’s water supply for irrigation, and it wasn’t long before his efforts started to bear fruit. He now grows peanuts, tomatoes, broccoli, aubergines, cucumbers, potatoes, melons and corn in his garden. What he doesn’t eat himself, he distributes among his colleagues.

item goes green

This free produce has been very warmly received by colleagues and is put to very good use. And, naturally, Sun’s methods are green from start to finish, with no pesticides or fertilisers being used. item staff can quite literally watch the fruits and vegetables grow before their eyes – as nature intended. Mr. Sun is now the food supplier of choice for a growing number of people. Repeat visitors to the site are constantly amazed at the size that the once small garden has grown to. The photos in our image gallery only show half of the vegetable plot. One thing is clear – item will continue to support Sun and his sustainable project.

Engineers have been continuously developing the humble bicycle for near on 200 years, inventing new approaches for better drives, lighter materials and even a revolutionary bell that might just make our D30 transporter bike even better.

The articulated crank drive

The ringing navigational light system

Textile bicycle spokes

Having examined the general principles of Industry 4.0 last week, we thought it was time to go into a bit more depth, specifically by looking at an exciting project from the Laboratory for Machine Tools and Production Engineering (WZL) at RWTH Aachen University. The project centres on a test bench that is used to show how sheet forming can benefit from a combination of wireless sensors and artificial intelligence. It is also about breaking down the preconceptions and anxieties that many small and medium-sized enterprises (SMEs) have about the digital revolution.

Digital SMEs

People and technology – hand in hand 

Industry 4.0 for SMEs 

These days, here in Germany, there are few, if any, buzz words that crop up in our sector more than “Industry 4.0”.  Often, people assume that everyone knows exactly what it’s all about, and the same can be said of other popular related topics such as the “Internet of Things”. So what does it all actually mean? What are the principles at play? What kind of role do people have in all this? To answer these questions, we are looking at three aspects that we believe are essential.  

1. Industry 4.0 is the next step in a long process of development 

The term Industry 4.0 was first coined at the Hannover Messe trade fair in 2011. It comes from an initiative of the same name launched by the German Federal Government as part of its comprehensive High-Tech Strategy. It describes both the fourth stage in the process of industrialisation and a specific target. The previous industrial revolutions have been well documented. While the first revolution was ushered in by mechanisation (keyword: loom), the following two were triggered by mass production and the integration of computers into the production process.

So how does Industry 4.0 differ from the phase of industrialisation that preceded it? Put simply and succinctly, it is about networking – between man and machine and between different machines. The key aim is to combine two principles that are actually opposites, strictly speaking – production line manufacturing and custom manufacturing. It is also referred to as mass customisation.

2. All roads lead to the smart factory

The concept of a smart factory makes the rather abstract idea of Industry 4.0 easier to grasp. This is where the Internet of Things comes into play, i.e. non-human parties communicating with each other. That could be a plant sending out a signal that it needs new material and the smart factory automatically and independently forwarding this information. The communication between these “things” takes place through the Internet or a cloud. All the elements involved are represented by a software agent.

This resolves the problem that workpieces don’t have the technical capabilities to communicate on their own. Another area associated with the Internet of Things concerns “cyber-physical systems” (CPS), whereby the workpiece is the physical element and the software agent the digital element. Humans can still actively intervene, for example by using mobile end devices to monitor processes or change individual parameters. Although some small and medium-sized enterprises are concerned about Industry 4.0, this anxiety is unfounded, as existing plants don’t have to be replaced in most cases. Often, pre-existing plants can be fairly easily upgraded to enable IT-based communication.

3. Industry 4.0 still needs people

Given the visions of the future that Industry 4.0 promises to deliver, it’s understandable that some may at first fear for their jobs. After all, there are plenty of science-fiction movies out there to support that view. However, although these fears and others like them are understandable, they are also ultimately unjustified. Of course it goes without saying that the way we work will change in the future, but Industry 4.0 is not about replacing people with intelligent machines – on the contrary, workers will have more complex tasks to complete.

More than ever before, employees in industrial enterprises are being asked to adopt an interdisciplinary approach, make decisions quickly on their own initiative and adapt to complex processes. This will bring clear benefits to Germany as a location for business. Our country has a highly skilled workforce and will continue to be well placed in that regard. Nobody need fear their (future) robotic colleagues!

Whether jewellery, textiles or prostheses, the possibilities that 3D printing offers seem to be growing all the time. There is currently even a drive to print whole buildings, which is known as contour crafting. The process discovered by American Chuck Holl in 1983, when it was referred to as stereo lithography, seems to have since developed into something from a science fiction film. All the same, it doesn’t always have to be spectacular – quite the opposite, in fact. 3D printing also unlocks striking possibilities in mechanical engineering, an area known for being down to earth. The following piece on three-dimensional printed prototypes explains ... 

What 3D printing is all about

Using CAD data as a basis, 3D printers print several layers of a material such as plastic, metal or ceramics one on top of another. In an industrial context, 3D printing is also referred to as “additive manufacturing”. Unlike subtractive processes, which rely on the removal of material, one of the key features of additive manufacturing is its very economical use of materials. For example, while CNC processing requires that a certain amount of material is milled away, 3D printing uses only what is actually needed. 

Rapid prototyping – added certainty for engineering 

Rapid prototyping is a direct reaction to the rapid throughput cycles that dominate industry, leaving no time to manufacture pre-series parts or models. Fundamentally, rapid prototyping has the same objectives and advantages as conventional prototype building. It is about studying preliminary versions of parts to identify potential weaknesses at an early stage. This smooths the transition between planning and engineering stages, thus avoiding the high costs that could arise as a result of manufacturing faulty parts.

The precision and speed of 3D printing makes it perfect as a rapid prototyping technology. However, in the electronics sector, it is important that all the materials used are also ESD-safe. Unfortunately, conventional 3D printing materials do not exhibit the crucial properties that are necessary. There is an easy way around this problem though – carefully applying a surface coating to printed prototypes protects them against electrostatic discharges. Brittle, simple plastics are basically the recommended materials for 3D printing.

But take a closer look and all is not what it seems – it’s a toy car! What you’re looking at is a fully functional car wash, but in a scale of 1:10. It is the product of an international collaboration between two vocational colleges, Robert-Bosch-Berufskolleg in Duisburg, Germany, and ROC Nijmegen in the Netherlands. Some 20 students from each college joined forces in mixed teams to impress a panel of judges with the quality of their miniature car washes. All the designs were built using our MB Building Kit System.

Cross-border cooperation

The project was launched by “Ler(n)ende Euregio” and emerged from the fact that many mechatronics and electrical engineers living and working close to the Dutch/German border have customers based in the country next door. In most cases, English is used as the technical lingua franca, which makes it all the more important that both German and Dutch students learn how to work with partners from the other side of the border. Both direct communication and general cultural differences are equally important. While last year’s round of the project was held in Duisburg, this year’s was staged in the land of windmills and canals.

But what exactly is Euregio? It is a cross-border collaborative network that aims to encourage development in the areas of business and culture. “Ler(n)enden Euregio” focuses specifically on Euregio Rhine-Waal – the border area between Arnhem, Nijmegen, Cleves, Wesel and Duisburg. It is a grouping of vocational schools, training centres and state institutes that are working together to make sure trainees and students are familiar with the ins and outs of working life in their neighbouring country. This ensures not only that they gain valuable intercultural skills, but also that they will have better future prospects on the European labour market.

Twice the expertise for car wash construction

Tasks were clearly allocated among the mixed teams. While the up-and-coming mechatronics engineers from Duisburg looked after programming and controls, the future mechanical engineers from the Netherlands were responsible for the car wash modules. It was a fundamental requirement from the start that all the car washes should be compatible with the control systems used in the neighbouring country. Other than that, the teams were free to unleash their powers of creativity, which led to remarkable results.

The showdown was held on 4 July 2016 in Nijmegen. The mixed German and Dutch teams had to try and sell their car washes to a fictional company. A panel of judges made up of teachers and trainers first checked the functionality, cleaning performance and design of the car washes. Other important factors included how well the students presented themselves, demonstrated their solutions and communicated. Given the all-round enthusiasm for the project, there is no doubt that it will be carried forward. Next in line is likely to be a project between ROC Nijmegen and Berufskolleg Rheydt-Mulfort in Mönchengladbach.

Directech is our exclusive sales partner in South Africa. Based in Johannesburg, the company specialises in automation, industrial robot solutions and tool making. This year, 16 young people who are studying mechanical engineering, marketing and business are taking part in a newly designed, in-depth internship programme designed to give them “on-the-job” training. In this blog post, we’re going to take a closer look at the concept and introduce two participants.

Young people getting involved 

Despite strenuous efforts, youth unemployment is still shockingly high in South Africa. In 2015 it hit 51.5 percent (men: 47.1 percent; women 56.9 percent). Directech is well aware of the situation and is determined to live up to its social responsibilities. Two individuals are appointed to look after each intern: one is a head of department who takes the role of supervisor, the other is a contact from Business Development who acts as a mentor. Directech takes the concept of mentoring very seriously, which is why the interns themselves are also urged to be active role models for younger people, particularly younger relatives who often live far away in economically underdeveloped regions. 

A virtual company

The programme centres on work in a fictional company, fictional in the sense that it is not registered and doesn’t sell any products, either. However, it’s not a game – quite the opposite in fact: Internally, the company is treated as if it actually exists. Every participant heads up a department as appropriate to their area of expertise and is given all the relevant authorisations. Additional training measures are implemented in parallel to help them exercise their duties, such as courses on aspects such as social skills, finances, ethics and etiquette. Each participant working in mechanical engineering must also select a product that they will then oversee closely.

Once the product is in place, the first job is to put together a business plan, a task with a great deal of practical relevance. If Directech is not able to offer interns a job, it provides solid support in helping them gain their independence. In that sense, the fictional company is designed to help interns get fit for the future – both their own and that of South Africa. To put it more precisely, they are being trained as future entrepreneurs who will go on to create jobs.

Introducing two interns

Lenny Matome Ramaselele has come a long way in his internship. Not only is he an assistant to the Product Manager for our profiles, he is also the Managing Director of the fictional company and has already worked on the Directech trade fair stand twice. However, Lenny’s prospects were anything but rosy at the outset. He seemed to be plagued by bad luck – barely had he arrived in Johannesburg than he was robbed, sustaining injuries during the mugging. However, intensive one-to-one meetings and a step-by-step approach to major tasks have helped him continuously build his confidence. He is no longer hiding his light under a bushel – he is realising his full potential.

Ayanda Mqamzana didn’t have things easy, either. Despite training in automation technology, she hadn’t been able to find a job in the sector and had to scrape by. Generally speaking, it is exceptionally hard for women in South Africa to break into this male-dominated sector. What’s more, Ayanda’s family were previously dependent on her work as their sole financial income. That made it very difficult if her wages were paid even a little late, as so much depended on them. Once Ayanda had completed a refresher course in automation at Directech, she was finally able to show everyone what she is capable of. Her perseverance and thirst for knowledge are hugely valued by her colleagues.  

Carrying out a retrofit, i.e. upgrading an existing plant or machine, is a striking alternative that is proving very popular. To put it in more specific terms, retrofitting involves incorporating new components into an “old” solution to bring it up to the state of the art. The end result is usually a clear improvement in efficiency, error avoidance and speed. What’s more, if you’re smart about it and adopt a step-by-step approach, you can complete an optimisation/modernisation project like this without significant downtime. 

The benefits of retrofitting

The general tendencies in mechanical engineering are conducive to retrofitting. For example, the mechanics of a plant will often continue to function perfectly even after a long service life. Far from being old scrap, they offer the perfect framework for applying the latest methods in control, automation and drive technology. This approach produces a promising hybrid of tried-and-tested technology and cutting-edge solutions.

However, there are more advantages to retrofitting besides just technical factors. If you compare the costs for a new acquisition with those for a retrofit, the latter can be between 40 and 80 percent lower. What’s more, under certain circumstances, only the attentive optimisation of an existing plant can enable it to achieve its full potential. However, it’s important not to generalise too much when considering the above advantages. After all, everything depends on the condition of the specific plant in question. Nonetheless, a retrofit should always be considered as an alternative to a new procurement. 

When is retrofitting worthwhile?  

The above-mentioned cost factor is just one of many reasons why retrofitting can be a good idea. Even if your aim is to boost production output or product quality, this approach can help you achieve a great deal. Companies can hit real trouble if urgently needed spare parts are no longer in production, but retrofitting can be an effective solution to precisely such a dilemma. What’s more, downtime and maintenance costs can be significantly reduced through this approach and employees don’t need to spend time familiarising themselves with completely new systems.

In addition, retrofitting can be a useful answer to questions such as: What do I do if occupational health and safety guidelines change? What do I do if the user friendliness of my existing machinery no longer meets current standards? How suitable is my plant for integrating IT?

It’s well known that we at item are big sports fans, but what exactly do a sprinter, archer and bodybuilder have to do with linear technology? They all make an appearance in our Automation catalogue! The idea was to find a clear and entertaining way to highlight the performance of individual dynamic components, which sometimes have very different strengths that are not readily apparent. For example, linear guides with timing-belt drives are extremely fast, while guides with a rack drive are the best option when working with heavy loads. It was decided that these features and more besides should be depicted in the catalogue by an action shot showing an appropriate sport.

Preparations get under way 

We soon realised during the concept phase that we would have to stage a photoshoot of our own, since using archive pictures simply wasn’t an option. Photographers and agencies were invited to submit bids, and one such bid came in from Jürgen Nobel, who was completely unknown to us at the time. However, while browsing the website of the baseball team we sponsor, the Solingen Alligators, we came across some sporting shots that ticked all the boxes. As it happened, the photographer behind those shots was Jürgen. Since he brought a great deal of experience in sports and the ideal complete package – including the right kind of personality – we ultimately decided to award him the contract. What followed was an intensive and very fruitful collaboration. Based on the requirements we set out in our detailed briefing, Jürgen developed suggestions for models, clothing and props.

Of course, we didn’t want to book fashion models and just kit them out to look like athletes, so all the pictures are of genuine sportspeople who model on the side. For example, the sprinter who brings his own interpretation of “dynamic” to the cover of the catalogue is African sports student Ismail. Naturally, we had to fly the flag for Solingen, too, so Michaela, who comes from the city and regularly competes in archery events, is also featured. Leonard, meanwhile, is a goalkeeper for an amateur football team and muscleman Yas – although not a professional bodybuilder – certainly knows all about the dynamic movement of heavy loads.

On your marks, get set, go!

The photoshoot was held in Essen over three very busy days at the end of September 2015. Indeed, Jürgen feels right at home in the Ruhr region, which is also where his office is based. Props managers and assistants worked their magic to transform the hired studio into a sporting arena and nothing was left to chance. Since each shot had been intricately planned using storyboards, the shoot made rapid progress, despite the heavy workload.

What’s more, the same approach used when picking the models was also applied to the props – authenticity was the number one priority. That was the only way to make sure the pictures would convey the dynamism required. So, when you look at the picture of Sofia elegantly leaping a hurdle, you can rest assured that it is a genuine, competition-grade hurdle. There are of course similar examples for domestic use, but experts would spot them instantly. Thanks to all his contacts, Jürgen had no trouble laying his hands on all the accessories and sports equipment imaginable from clubs. Special care was also taken to ensure all the clothing and props also matched our corporate design – red and white are very prominent, while overly garish colours are nowhere to be seen.

To give you an even better idea of the process, we have some video footage of the photoshoot:

Whether a mobile juice bar, ChemCar, soapbox or Euro 2016 oracle, we’ve already seen some pretty striking and unusual examples of how our products can be used. That got us thinking – what kind of ideas do our colleagues at item work on when they get home from their day job? When we looked into it, we came across two very interesting hobby projects and of course we couldn’t keep them to ourselves! We also found out about a project in Israel which, although not run by our colleagues, is no less remarkable.

Stable compost protection

One of our colleagues from Nossen was having problems with the composter in his garden at home. Not only was the old design starting to look a bit tired, but some nightly visitors were also gnawing away at the plastic to get at the tasty contents of the compost inside, while others were managing to remove virtually every type of lid imaginable. There was no doubt that the compost was a tempting tasty treat for these creatures, so a new and better solution had to be found!

The keen gardener sat down with one of our project engineers to design a new composter based on our profiles. Their ideas were expertly transformed into a practical solution and the compost is now finally safe from intruders. The design is based on the aluminium profiles of Line 8 40x40 with closed profile grooves. There is a large hinged filler hatch and simple screw-fastened removable flap at the top and a large unloading opening in the front, at the bottom. Aluminium Perforated Sheet has been used to provide ventilation at the sides and top.

Fireside door with family photos

Another colleague unleashed his creativity to inject a bit of fun into something pretty practical, using Profile X 8 40x40 to build a fireside “photo door” for the living room. The door can be opened to access the heating distribution system, electrics and the fireside accessories. Magnetic Door Stop 8 holds the door firmly shut. Meanwhile, our Panel-Fixing Strips have been fitted to the front of the door to hold family photos in place and create a stunning design.

Simply stylish – item supports a passion for fashion

We recently received a report from our Israeli sales partner, Automation Yeruham & Co Ltd., in Cholon, which had been commissioned by a prestigious firm of architects to fit out a fashion boutique. The shop in question is in the Dizengoff Center, a shopping mall in the heart of Tel Aviv. On working days, up to 20,000 visitors pass through the huge building, which was the first of its type in Israel and was built between 1972 and 1983.

Some six weeks after first getting in touch, the architects had finally completed their designs. Now it was time for our partner to get to work. The end result included exceptionally stable changing rooms with additional mirrors, chic sales desks, rear walls, partitions, counters and shelves – all built using profiles from our MB Building Kit System and our panel elements. You can take a look at the elegant decor of the boutique here:

As Germany’s biggest university for technical courses, Rheinisch-Westfälische Technische Hochschule Aachen offers more than 43,000 students outstanding learning facilities and opportunities at 260 institutes organised into nine faculties. Research carried out at the Institute of Imaging & Computer Vision (LfB) centres on practical applications for high-resolution imaging and intelligent image recognition.

The problem with recycling electronic waste

Matthias Breier and his team are working on one of the most pressing problems posed by our modern consumerist society – printed circuit boards and other electronic components are installed in virtually everything. What’s more, these objects are themselves made up of a whole range of materials – and that is precisely what presents such a challenge when it comes to recycling discarded devices. Using standard technology, it simply isn’t economically viable to efficiently separate materials that are fused together in such a small space.

Compared to the high-tech claims of the entertainment industry, current recycling methods are perhaps best described as robust. Electronic waste is sorted, shredded and then melted down. Metals – primarily gold, silver and copper – are extracted from this melt using electrochemical processes.

Larger yields thanks to targeted recycling

Conventional recycling processes hit their limits when it comes to recovering metals such as tantalum and rare earths, which are only present in very small amounts in waste circuit boards. There is another problem, too: In the case of many devices, there is no publicly accessible information on the type and quantity of materials that they contain. Manufacturers often guard this kind of information jealously from their competitors.

This is precisely where image processing comes into play. Breier’s team has developed a special test bench where waste circuit boards can be filmed with extremely high-resolution imaging equipment. The resultant images can be used to identify precisely what components are installed, and therefore help determine the material composition – all without any documentation. The end result is a customised list of characteristics for each circuit board that the recycler can use to decide how to sort waste products on a case-by-case basis. When used in conjunction with slightly modified techniques, recyclers can significantly boost the recycling rates they can achieve.

Linear technology for precise and repeatable movements

However, the current research phase is focused primarily on testing different technical approaches for optimum component recognition. Consequently, it is imperative that the test bench allows the operators to take images from an identical position relative to the object, so that the chosen methods can be compared on an objective basis. Very short and precise movements are also crucial, so that the circuit boards can be imaged in extremely small sections that are then compiled into one high-resolution panoramic image.

By working with us, the team created an imaging bench comprising a stable substructure made of aluminium profiles and two Linear Units combined in a criss-cross arrangement. The object to be imaged, which is mounted on a carrier installed on the Linear Units, can thus be moved in two dimensions. A frame has been installed above this system and fitted out with an industrial camera and a range of lighting systems. Moving the object relative to the camera in precisely defined increments allows the operator to create a (3D) simulation of any stereo structure. The images are then analysed on the computer in subsequent stages.

Low makeready times thanks to item profile technology

In an effort to find an optimum solution that can be put to use further down the line in an industrial environment, the test bench is to be extended in upcoming development stages with large-area LED lighting (barlight) under the frame. Thanks to our fasteners and T-Slot Nuts this is very easy to achieve and the imaging bench itself will stay very stable. Breier’s team likes to use the item clamp lever as an ideal tool for quick adjustments.

Admittedly, it all started as just a bit of fun in the break room, where a wall planner for the European Championship in France has been put on display. Someone pointed out that Paul the Octopus had made it into the headlines as far away as China. Unfortunately, Paul died at Sea Life Center Oberhausen in October 2010. “Then why don’t we build our own oracle,” suggested our colleague Steffi, to much laughter.

The challenge

The idea became more than just a joke for our trade fair team. Can you actually predict how a football match will end using item components? How do you add sufficient chance to the way the ball moves and what’s the best way to make it move? The team’s ambition started to kick in.

Niko, one of the trade fair team, drew some inspiration from a Karakuri exhibit. Indeed, he and his colleagues don’t just build the actual stands at exhibitions and trade shows, they also construct the benches, cabins and displays that enable us to showcase our products to visitors.

Low-cost automation – no batteries required

Karakuri is a Japanese term that refers to mechanical automation, i.e. automated procedures that are not powered by electricity or regulated by electronic control systems. In a Karakuri bridge, for example, containers are lifted over an opening.

In the space of a day, Niko had assembled the prototype using Profile Tube System D30. However, the first test was disappointing. The Karakuri Oracle predicted twice over that Slovakia would win. Everyone agreed – it obviously wasn’t working.

Following Germany’s 3:1 defeat at the hands of Slovakia, the ‘football experts’ were somewhat sheepish when they gathered in the break room on Monday. The mood has improved significantly since Saturday though. The second test worked, too – the Karakuri Oracle correctly predicted a win for Germany.

Make your own prediction and win a FIFO dog!

All this led to a new idea. The Karakuri Oracle is just too good to keep to ourselves, so we’ve decided to film its predictions before each day that Germany is playing and post the results on Facebook. You can enter your own predictions in the comments section. For each match, everyone who guesses the final score correctly will be entered into a draw for an original item FIFO dog.

All this led to a new idea. The Karakuri Oracle is just too good to keep to ourselves, so we’ve decided to film its predictions before each day that Germany is playing and post the results on Facebook. You can enter your own predictions in the comments section. For each match, everyone who guesses the final score correctly will be entered into a draw for an original item FIFO dog.

You can find out more about the Karakuri Oracle and our predictions game on the item Facebook page. Take a look and give us your prediction!

Ergonomic work benches account for the fact that every employee has different physical characteristics. However, what do you do when these characteristics include physical disabilities?

This is where the barrier-free concept comes into play. Whether you’re talking about a building or a communications medium like a website, the concept is fundamentally the same – it’s about ensuring accessibility for all, regardless of age. When it comes to the world of work, this means there should ideally be no limitations on who can use a work bench, regardless of permanent physical limitations or age-related conditions. The following article sets out the criteria and benefits of barrier-free work benches.

Barrier-free design for the workplace

Here are a few examples of the kind of issues that need to be considered when setting up barrier-free work benches: Employees who are in a wheelchair or have difficulties walking or standing have a significantly restricted handling area. In most cases, they cannot stretch or bend to reach things that are any more than an arm’s length away. In the case of excessively large reaching distances, the torso also has to be moved to ensure the body is balanced, which makes reaching more difficult and increases the risk of stress-related back and shoulder complaints.

The height of employees is closely related to this. The optimum table and working height for women and men differs by an average of 125 millimetres. It is well known that height-adjustability is a decisive design factor for ergonomic work benches and it is even more important for their barrier-free counterparts. In basic terms, the following applies: A work bench that satisfies the stipulations in DIN 33 402 and DIN EN ISO 7250 is suitable for around 90 percent of the population.

Breaking down barriers – tapping into hidden talent 

There are around 9.6 million people in Germany today who are living with a disability, 7.1 million of whom are seriously disabled. Unfortunately, despite the current scarcity of skilled workers, this section of the population is often overlooked. There is a clear misunderstanding as regards the potential that they offer. Indeed, young people with physical impairments often have excellent training and education – in many cases, much better qualifications than the average non-disabled person.

According to the German Federal Employment Agency, approximately 60 percent of severely disabled people who are unemployed have a vocational or academic qualification. Nonetheless, they are virtually excluded from the labour market. In other words, there is a talent out there that employers could harness with a barrier-free work bench system. Occasionally, all it takes to facilitate access to the workplace are a few modifications such as special equipment or a ramp.

Benefits for companies

When companies decide to put in place barrier-free work benches and employ people with physical limitations, they are unlocking countless benefits. Firstly, they gain access to exceptionally well trained and appreciative employees. In the long-term, they are taking positive steps to counteract the lack of skilled workers by expanding the pool of potential employees. What’s more, all the employees in their company can stay fit for work for longer. Companies that opt to break down barriers like this are thinking ahead and looking out for their future.

There are also added benefits for the company’s image. Businesses that adopt this approach can present themselves as attractive employers who are keenly interested in the wellbeing of their workforce and want to meet their responsibilities to wider society. Companies known for using barrier-free work benches also stand a better chance of securing public contracts. Operational processes and thus efficiency in general are also significantly improved by pursuing more ergonomic working practices. Moreover, companies in Germany can avoid having to pay the statutory financial contributions that are mandatory if they fail to meet their legal obligation to employ disabled workers. These mandatory contributions are based on the annual average number of jobs at the company.

The following interview with our design team offers a detailed insight into all this and more.

Design is very important at item. Why is that?

Today, design is becoming increasingly important as a way of standing out from the competition – even in an industrial context. It’s not just about the individual product, but about the overall image of the item brand – it’s corporate identity, if you like. This identity runs through every part of the company, from the company architecture, print media and website to trade fair stands, the company fleet, work clothing and even promotional gifts. Every aspect of the company speaks the same, very clear design language. Design and innovation have always been high on the agenda throughout the company’s history. Indeed, the owners’ affinity with design has played a key role since the very start.

How does this focus on design manifest itself in the products?

All our products have to meet stringent design requirements in terms of both form and function. That includes, for example, their ergonomics, look, feel, material and colour. The design and product development process starts with identifying customer requirements, ergonomic demands and the relevant commercial and technical circumstances. Based on that, the designers work with the engineers to develop, check and optimise concepts.

We maintain close, interdepartmental cooperation that generates synergies. This helps us run an efficient product development process and produce a wide range of products every year that boast outstanding technical and design credentials. What’s more, we are very proud that item products are regular recipients of prestigious design awards. For customers, these awards are proof of design quality.

Are ideas turned down very often because of design?

Over the years, the design team has developed a design language that is applied to all new products. Since design is an integral part of the entire development process, ideas are rarely turned down. Feasibility and cost-effectiveness are always a real priority in product development.

How important is design to new products? What kind of weighting does it have?

There are no half measures. Particularly when it comes to the new products, it is extremely important to pursue a standardised design guideline. And, of course, design is also a commercial factor. Ultimately – whether you’re operating in the consumer sector or in an industrial context – it is people who decide whether or not to buy something. A well designed, easily understandable product has a much better chance on the market.

So, can a product be “over-designed”? What would be the down-sides?

Design covers a lot of factors. A good product will account for all those factors and strike a balance between them. If there isn’t this balance, then it simply isn’t a good product. In that kind of context, “over-designed” can mean a lack of balance between form and function, for example. That’s particularly bad in an industrial concept, where a product’s form has to enhance its usefulness. That is why our design approach is very subtle, pragmatic and accessible. That’s the difference between design and art!

What’s a typical working day in the Design department like?

As designers, we work with the engineers on a whole range of projects in various stages of development, so our working day can vary a lot. Some projects are just being launched, so we’ll be carrying out wide-ranging market analyses for those. Others will be in the concept phase and we’ll be sketching out the first concepts by hand on paper. When the ideas start to take shape, we’ll use a CAD program to develop them on the computer. Further down the line, we’ll create the actual prototypes, which are produced using a rapid prototyping process or as milled parts.

The prototypes are the basis for ongoing discussions, functional testing and ergonomics checks. Twice a year, there’s also a photoshoot for our new product catalogues, which is also organised and supported by designers. There’s a lot to do. Every day brings exciting tasks.

High stock levels are a huge cost factor, so avoiding them is a key element of the anti-waste message conveyed by the seven Muda. Storing materials and goods always ties up capital and brings with it the risk that they could be damaged.

The just-in-time method is a proven logistics tool that tackles this problem by ensuring suppliers cater precisely to the needs of manufacturing companies. However, it does not solve the problem that arises when the specific sequence of deliveries is all-important. What should you do then? One suitable, lean solution is the just-in-sequence method.

Basic principles of just-in-sequence

Just-in-sequence (JIS) is a logical extension of the just-in-time (JIT) principle. It is not just about supplying the customer with the right quantities at the right time, it’s also about doing that in the correct sequence. For example, the following applies when using the JIS method: Besides ensuring that the right number of components or modules are supplied at the right time, the supplier also makes sure that they are delivered in the same order that they are installed. As a result, the customer’s assembly sequence determines precisely how supplies are delivered.

JIS is particularly helpful when products are being manufactured for further processing, such as in the electronics and automotive sectors. The production sequence is usually established a number of days before assembly work starts, which means that just-in-sequence can also be implemented over long distances in the meantime (long-distance JIS). Naturally, more detailed sorting of this type fundamentally requires closer communication between supplier and customer, which is usually handled through EDI (electronic data interchange) systems. EDI systems enable two companies to share standardised business documents automatically and electronically, which saves a great deal of time.

JIS – benefits and criteria

The immediate advantage of just-in-sequence for workers on the production line is that it doesn’t generate any extra work for them. They can use the parts supplied to them straight away, without having to waste any time sorting through deliveries to find the part they need next. Since the capital tie-up associated with high-quality and/or bulky parts is well above average, these are particularly suitable for JIS, which can considerably reduce warehouse stock. This in turn lowers storage and personnel costs and minimises the risk of goods being damaged while in storage. 

When it comes to material that involves longer shipping times, JIS is of course less suitable – as is the just-in-time method, too. The longer the shipping distance, the higher the probability that unforeseeable circumstances will disrupt the process chain. Since the entire supply chain is involved, customers also have to respect corresponding quality guidelines – although the greatest responsibility lies with the supplier. Incidentally, that is also why suppliers in the automotive sector are often located in the immediate proximity of the production facilities they serve. This physical closeness enables them to significantly reduce their delivery times and ensures they can react extremely quickly to any transport or sequencing problems.

He is also a sports educationalist, a member of the governing body of the Association of German Back Schools (Bundesverband der deutschen Rückenschulen e. V., or BdR) and the owner of Rückenschule Hannover (Hannover Back School).

The term “Back School” suggests there’s a lot to learn. Is ergonomics missing from the production curriculum in a lot of companies?

The Back School is not the same as ergonomics. A back school will cover both behaviour-oriented and condition-oriented prevention. Behaviour-oriented prevention focuses on what an individual can do for themselves, such as lifting and carrying loads in a way that is gentle on the back, doing relaxation and strengthening exercises and being physically active on a regular basis.

Ergonomics tends to focus on condition-oriented prevention, in other words, the surrounding ergonomic and organisational circumstances or environment. That includes designing sitting and standing workstations, deploying lifting and carrying aids and regularly changing working tasks. Ergonomics is a key element in the training of occupational medicine practitioners, safety specialists and workplace designers.

In your day-to-day work, what are the most frequent problems you encounter that are caused by a lack of ergonomics?

Poor ergonomics often results in inappropriate constrained postures when sitting, standing, bending and lifting. This leads to discomfort and, in the long term, even musculoskeletal complaints. Besides having a detrimental impact on product quality and productivity, it also impacts on employee job satisfaction.

Do workers and decision-makers in industrial companies still tend to view ergonomics automatically as some kind of feel-good exercise for office workers?

I can’t confirm that’s the case in small and medium-sized enterprises (SMEs). But in any event, when it comes to bigger companies, they’re are already one step ahead in ergonomics. All in all, recent years have seen a big improvement in the level of awareness for ergonomic measures in the industrial sector. This process has been accelerated primarily due to company health management activities and a recognition that the very make-up of our population is changing. All the same, there is still a lot of work to be done in terms of putting our knowledge and understanding of ergonomics into action.

What are the direct and long-term consequences if companies don’t put in place sustainable ergonomic working conditions?

Ergonomic working conditions are a clear legal requirement enshrined in German occupational health and safety legislation. Employers are required to provide ergonomic workstations. What’s more, companies that don’t implement ergonomics will not be able to survive on the market in the long term. The number of sick days will rise, experienced workers will avoid the company and product quality and efficiency will decline.

What kind of psychological impact does a high-quality work bench system have on employees?

A high-quality work bench system on its own is not effective on a psychological level. It is only when employees understand the benefits for their health and the working process that their job satisfaction improves. That is why ergonomic work bench design should go hand in hand with a comprehensive programme of theoretical and practical training and induction for the workforce. They need to be brought into the process as experts at their workstations.

Why is it important to differentiate between work that is more ergonomically efficient and work that is faster?

Expecting people to work faster is a very one-dimensional and short-sighted approach. Working at a high speed can lead to quality issues and, over the long term, to health complaints. Ergonomically efficient work benches are the basis for quality, efficiency and health.

Are ergonomic working conditions enough to ensure workers stay fit for the long term or do we all have to make a real effort to keep our backs healthy?

Ergonomic working conditions are one element in efforts to keep people fit for work. Other elements include workplace organisation, leadership skills and the specific circumstances of employees. Everyone has to take responsibility for their own physical and mental wellbeing, too.

How much time each day should we be investing in keeping our backs healthy?

It’s not really about spending a set number of minutes or hours, it’s about awareness and having the right kind of attitude to your health. Everyone should be willing to keep their back healthy, both at work and in their free time. Someone who is conscious of their back and its needs will maintain a healthy posture, avoid monotonous movements and constrained postures, be physically active on a regular basis and try to strike a balance between stress and relaxation.

To what extent can employees be actively involved in the ergonomic optimisation of their work benches?

It is essential that employees are involved in the ergonomic optimisation of their work benches. That can be arranged through company suggestion schemes, quality workshops, ergonomics workshops, health talks, work situation analyses, health forums and health days. Ergonomic training with theoretical and practical elements is very effective.

Could you show us some of your favourite exercises that can be done in short breaks or as part of a morning routine?

These are my favourite exercises:

Further information is available on the website of Rückenschule Hannover.

Professor Schmauder has been the Chair of Labour Sciences at Technische Universität Dresden since 2000 and is an expert in workplace organisation, ergonomics, occupational health and safety and human resource management.

Which disciplines are relevant to research into ergonomics at the assembly work bench?

Ergonomics is an interdisciplinary field, which is also why it is so effective. It all starts with the person and their needs, so we need to understand physiology. We also need to have a grasp of biomechanics for forces and movements. Occupational hygiene is important for the working environment and occupational psychology for the actual content of work. When it comes to workplace organisation, a grounding in business administration is essential, while engineering is crucial for actually putting concepts and ideas into practice. It is a truly interdisciplinary field. Ergonomics specialists need to understand both the work and the people doing it and combine both aspects.

What kinds of risks do ergonomically designed workplaces help to offset?

Ergonomics is not just about risks, it’s about humanity and cost-efficiency, it’s about optimizing workplaces. Poor body posture and movement sequences need to be avoided so that people stay fit for work for the long term.

What do we need to take into account when putting ergonomics into practice?

We need to think about environmental and behavioural ergonomics. Ergonomically designed workplaces need to provide the right environment and conditions, while people also need to be trained from a health and safety perspective, so that they can and do use the facilities that are available to them. Such facilities could be a work bench or chair that personnel can adjust to suit their specific personal needs.

There’s a lot of talk about the specific personal needs of employees. What does that actually mean?

Everyone is different. We’re not made by a machine that churns out identical, quality-controlled parts. Our specific personal needs – both physical and intellectual – also vary depending on the kind of training or education we have. Factors such as gender, physical dimensions and age are also important, of course.

What kind of role does a person’s age play, particularly with regard to demographic change?

As we get older, our needs change. In particular, our physical and sensory abilities start to decline. Other elements may stay stable or even improve. For example, our ability to learn doesn’t change and our social skills improve. However, it is important to take into account the growing gap between high and low performance amongst older employees. Factors such as pre-existing illnesses contribute to this, while healthy lifestyle changes obviously have a beneficial effect.

To what extent can aids and tools at the workplace compensate for this age-related performance variability?

Adjustability is the hallmark of sound ergonomic design – ensuring that all employees can create the ideal working environment for their needs. However, these technical requirements are just the first step. Employees also need professional support in working out what the optimum settings are for them. The end result of this collaboration can be applied directly to equipment using coloured markings or can be stored in a memory function when an electric height adjustment system is being used.

Why don’t separate, isolated measures usually have the desired effect?

Work itself is not static and short term, it is dynamic and long term. We have to look at the whole working sequence and not just improve a small subsection. We also have to consider whether a particular way of doing something can actually be sustained for the long term. For example, rationalising away movements at the work bench so that employees don’t have to stand up and walk a few paces might be efficient in the short term. However, over the long term, changes like that may not be beneficial for employees.

When it comes to implementing ergonomics at the work bench, what would you say are the benefits of a modular work bench system based on a building kit system?

When using a modular system, everything fits together and can be extended. The advantage of a screw connection is that it can be disassembled. Mechanical engineers learn that in their first semester. And that is exactly what systems like these have going for them – they can be tailored to the specific working procedures and the people who carry them out.

One objection to a holistic system like this, which we hear a lot, is that ergonomics is just too expensive. Why is that not the case?

Work bench systems based on a building kit system can be used in a whole variety of ways several times over. If a product range changes – which is often the case today – these systems can be adapted and there is no need to buy anything new. When you take into account their service life, work bench systems aren’t really more expensive.

What simple tools can companies use when they are selecting ergonomic factory equipment?

Companies can now use planning aids, online configurators and digital ergonomics systems that allow users to incorporate the human factor into the work bench as early as the planning stage. Thinking about who is going to be carrying out which sequences at the individual work benches at such an early stage helps avoid the need for changes. Planners should therefore have a basic grounding in ergonomics.

Processes can be easily automated using our linear technology – thanks to 25 preassembled solutions.

Process automation is increasingly a necessity in modern production. By lowering unit costs and boosting quality standards, industrial development has done a great deal to raise efficiency levels. However, benefits such as these can only be fully utilised if machinery and plants are one hundred percent tailored to the relevant requirements. This is precisely where our linear technology can deliver its benefits in full, primarily because it is preconfigured, flexible and accompanied by two web-based selection aids.

The fundamentals of linear technology

When it comes to automation, linear technology is one of the most popular solutions in industry. It is robust, reliable and easy to implement. But why “linear”? The reason is fairly straightforward – because the movement in this type of system travels along an axis. The slide, which carries the object that needs to be moved, travels forward and/or back along the axis.

Linear units can also be combined, which means they can support two and three-dimensional positioning. This approach can be used to execute complex sequences at a comparatively low cost. A crucial element in any linear unit is the linear guide, which is responsible for determining the direction of the motion and comprises two parts – the guide (rail) and corresponding transport element (slide).

An overview of linear guides

The two key components in a linear unit are 1.) the linear guide and 2.) the drive technology. There are basically three types of linear guide:

Roller guides

This type of linear guide uses rollers that run along cylindrical shafts. The design of the rollers supports play-free travel and ensures they cannot jump out of their guide. Advantage: Roller guides offer a particularly high level of flexibility.

T-slot sliders

These systems feature a profiled slider that runs along a profiled rail. Due to this profiling, the slide cannot come out of the guide track. Advantage: T-slot sliders are ideal for applications that do not have to be completely free from play and are generally recommended when on a tight budget.

Recirculating ball bearing guides

The key feature of these systems is their ability to accommodate high loads in a small space. In the principle of multiple points of contact, the rolling elements are arranged so that they run along one line and are finally recirculated along another track. Advantage: This system features low friction and excellent load distribution.

Drive technologies in linear technology

Cutting-edge drive technologies are always geared toward specific tasks. They can either be very fast or exceptionally accurate. The overall performance of a linear unit is determined primarily by the choice of drive technology, which has a significant impact on the precision, speed, carrying capacity and costs of a linear solution. The following drive technologies are available:

Timing-belt drive

This technology uses a toothed drive belt that locks mechanically around a toothed pulley that is driven by a motor. This mechanical interlocking eliminates slip and ensures that high forces can be transmitted. A timing belt comprises steel cables in a polyurethane sheath, has a long service life and supports a smooth running action. Advantage: This technology enables extremely dynamic movements and therefore short cycle times.

Ball Screw Unit

A Ball Screw Unit is based on a precision spindle. The speed and positioning accuracy of the system are largely determined by the lead on the thread. A non-turning drive nut that houses ball bearings is fitted to the spindle. These ball bearings circulate in the thread and ensure that the nut moves along a straight axis as the spindle turns. Because the ball bearings are very slightly larger than the track in which they run, they produce a pre-tensioning effect that eliminates play and supports load-carrying capacity. Advantage: Ball Screw Units are ideal when precise positioning and a lot of power are required.

Chain drive

Linear units with a chain drive transfer large forces in the direction of travel, but are limited in terms of positioning and travel speed due to their design. However, they exhibit excellent failure load, which means chain drives are often used for vertical applications. Advantage: Chain drives are resistant to problems caused by soiling, can transfer high forces and are also very suitable for vertical movements. This design is also particularly well suited to building conveyor systems with rollers, because the force in a chain drive can be converted into a rotary motion via sprocket wheels positioned anywhere on the linear unit.

Rack drive

The driven gearwheel in a rack drive interlocks with the straight rack to eliminate the possibility of slip. The rotary motion of the drive motor is thus converted directly into the rectilinear motion of the slide. This enables two applications: 1.) The load travels with the driven gearwheel. 2.) The drive is fixed in place and the load travels with the moving rack. Advantage: A rack drive is robust, can lift heavy loads safely and can position devices accurately even over long distances.

The advantages of our linear solutions

Since all projects come with their own specific requirements, they also require similarly specific linear solutions, which usually means engineers have to spend a considerable amount of time and money developing suitable technology. Not only do they have to identify the components that are called for, they also need to put them together to create a linear unit. Our Automation System takes care of all that for them – thanks to its 25 preconfigured Linear Units for a whole range of applications. What’s more engineers can rest assured that the Linear Units satisfy all technical safety requirements and will fit together perfectly. These basic models for typical tasks are supplied with drive elements, slides and accessories and are therefore ready to be installed straight away.

Engineers who opt for one Line get the optimum technology for their process. Moreover, each Line includes a selection of Linear Units in different performance classes that can be selected according to very specific needs. As there are no limitations on the drive train, our Linear Units are also entirely flexible, and this flexibility – combined with time savings – can significantly cut costs. On top of all that, our linear technology is of course fully compatible with the MB Building Kit System and, if any questions should arise, we are on hand to help – around the world.

For example, they generate emissions (such as noise, humidity or dust) or are located in a harsh or inhospitable environment. It is because of factors like these that processes need supply, extraction and IT systems – and enclosures offer a solution. XMS is a building kit system that has been specially developed for building enclosures and cabins for machinery and plants. It can be adapted to perfectly suit specific processes and applications. The frame structure is deformation-free, exceptionally strong and can be divided into different functional sections. Cables and supply lines can be run through cable conduits that are integrated into the profiles and are fitted with secure covers, ensuring easy access at all times without compromising on protection. Unbroken outer surfaces and close-fitting doors make it easy to keep production facilities clean, which also means XMS is ideal where sensitive processes are involved, as the following two field-proven examples show.

Testing is more than just studying

Practical research is a major focal point at Rheinische Fachhochschule Cologne (RFH) university of applied sciences, and particularly at the university’s LaborLaserTechnik (LLT) laser technology laboratory. Numerous research and development projects are carried out at the LLT in collaboration with various university, research and business partners. One of the LLT’s main aims is to leverage its many and varied partnerships for the benefit of students. As a result, they often form the basis of ambitious, forward-looking projects and final-year work – an approach that ensures everyone involved can benefit from close interaction between research and industry.

One of the key areas of activity in the LLT relates to the delivery of laser facilities. All the plants in the lab have been developed over the course of work carried out by students and the high-power diode laser plants are based on the XMS building kit system. The XMS system was chosen because it supports outstanding flexibility when designing structures and can be easily extended and quickly adapted to new requirements. However, other key features that impressed the university included the system’s door solution, the protection it offers workers from lasers, the features that stop dust getting into the enclosure and the integration of cables. The wide range of accessories also played a part. Thanks to all these features, the plants are perfectly equipped for future enhancements.

Creating versatile measurement environments

In 1985, Z-Laser Optoelektronik GmbH was the first supplier in Germany to offer lasers for use in industry. Today, the company is a market leader in several sectors, such as for pioneering lasers in the manufacturing industries. Lasers are used in a whole range of sectors. For example, they offer a much more accurate and straightforward alternative to existing workflows for cutting metal, wood and textiles. Lasers are also very useful in image processing, where laser illumination helps to automate optical quality controls by accurately recording the three-dimensional contours of both moving and stationary objects.

Z-Laser carries out in-depth testing at several test benches, the most striking of which is the large measurement workstation for line lasers. The actual measurement workstation itself is made of black anodized profiles from our MB Building Kit System. An XMS enclosure was built around it and features door solutions and panels that keep the workstation safely in the dark. A granite slab is mounted on the workstation and the measurement devices are installed on the slab. The laser that is being tested can be moved in any direction. Since the internal structure is connected to the outer structure by an elastic mounting instead of a rigid fixing, external vibrations cannot compromise measurement results. What’s more, thanks to the flexibility of the XMS profiles, the structure can easily be adjusted to suit new production sequences and the enclosure can be reused without any difficulty.

It was the turn of Adam Opel AG to host the annual awareness-raising day in March 2016. The campaign is a joint project run by the Association of German Back Schools (Bundesverband der deutschen Rückenschulen e. V., or BdR) and the Campaign for Healthy Backs (Aktion Gesunder Rücken, or AGR). The slogan for this year was “Ergodynamics – get your daily life moving!”

All the various discussions and presentations centred on one key question – what can you do to make sure employees are more aware of back health? It is hoped that a combination of ergonomic work bench systems and industrial training will translate into an altogether more back-friendly lifestyle in the medium term.

Ergonomics at the assembly work bench

Of course, adopting this kind of approach to ergonomics makes ergonomic industrial work benches even more important. The Work Bench System from item shows exactly what an assembly work bench based on the latest research and technology can do. Equipment includes high-quality, highly adjustable chairs from Dauphin HumanDesign®, lighting from Waldmann that has been optimised for use in industrial environments and ergonomic tools from Wiha. This impressive combination makes the Work Bench System from item the first – and so far the only – industrial work bench system to be awarded the AGR “Certified & recommended” seal of approval.

Presentations given by Prof. Martin Schmauder, Chair of Labour Sciences at Technische Universität Dresden, Ulrich Kuhnt, owner of Rückenschule Hannover (Hannover Back School) and ergonomics experts Jürgen Kalbeitzel and Reiner Grünen from Adam Opel AG highlighted why optimum ergonomics at the industrial work bench are so important. Everyone agreed that there are many challenges that work bench design has to tackle, particularly as back complaints are presenting increasingly early among younger employees while demographic changes mean that there is a growing number of older employees.

Keeping people in work for the long term

One important point in this context is that different employees have different needs that must be met if they are to work to their full potential – needs that can vary depending on their age, gender and experience. How a person is feeling on any given day and other psychological factors also impact on performance. When it comes to strength alone, employees over the age of 45 can be 20 percent less capable than considerably younger colleagues, depending on the kinds of forces in play. The ageing process of the eyes also means that a 60-year-old employee requires a luminous intensity of 100 Lux – more than double the amount of light that a 20-year-old needs.

Ergonomic work bench systems tackle these challenges with precisely defined handling areas, bright lighting, low-glare working surfaces, alternation between sitting and standing and versatile adjustment options that allow users to tailor the work bench to their body size. The latter point is especially important. If we compare 95 percent of the typical user groups in industrial production, the height difference between a small woman and a tall man can be more than 30 centimetres. Work benches that ignore facts like these will inevitably have a detrimental impact on the specific needs that have to be met for a worker to perform to his or her full potential.

Ergodynamics – the back-friendly lifestyle

According to data collated by the Robert Koch Institute, musculoskeletal complaints are the biggest cause of absenteeism in the workplace. Back problems often turn out to be protracted complaints that can force people to give up work before they want to. However, the actual spinal discs themselves are only affected in 5 percent of cases. By contrast, a weak point that is consistently overlooked is the lower musculature of the back. These muscles stabilise the spinal column like the counterweight of a crane, but activities that are carried out while sitting and spare time spent on the couch do little to exercise them.

That is why a healthy spinal column needs regular movement – and not just at work. All the same, the experts participating in the 15th Back Health Day in Rüsselheim agreed that none of these requirements could be met without willingness and motivation on the part of employees. From the very start, they need to be actively involved in optimising their workplaces in the pursuit of ergodynamics. Ultimately, it is the production workers who know best where processes and workflows can be adjusted. A high-quality work bench system is a sign that the company values its workforce. As such, it motivates and encourages employees to take responsibility and take the necessary steps to keep their back healthy.

Every business has a responsibility to society as a whole. We hear that an awful lot these days, but we’d like to show that there can be more substance to this well-meaning sentiment, which can so easily be dismissed as a cynical marketing ploy. Casting your eye over the various sports teams that we support will give you a good idea of how colourful and varied sporting life is in Solingen. Thanks to the commitment of everyone involved and some outstanding youth training, the sports scene in and around the city is thriving.

US sports in the city famous for its cutlery

You can’t talk about American sports without mentioning American football. And Solingen has something to offer in that area, too. Following a hiatus in the burly team sport after the Solingen Hurricanes ceased to be in 1998, the game finally returned to the city when the Solingen Paladins were founded in 2006. Since then, things have gone from strength to strength! In last year’s season, the Paladins took third place in the North Rhine-Westphalia league.

Unfortunately, baseball has yet to enjoy the attention it so richly deserves in Germany, but the Solingen Alligators are doing their level best to change that, winning the German Championships in 2006 and 2014. After their last win, they earned an entry in Solingen’s golden book  “We are really grateful for that recognition,” said the team’s coach, Norman Eberhardt at the time. His successor, experienced US coach Ron Frazier, can’t wait to get started when the championship season kicks off on 3 April.

Coordination on land and in the water

The TSG SolingenVolleys have been a successful volleyball team for 40 years. In 2011, however, they were given an extra special boost. Following the break-up of the men’s second division team at TSV Bayer 04, the team from Leverkusen moved to their coach’s home city. With the welcome reinforcement, the SolingenVolleys secured third place in their first ever second-division season. However, the real high point came only recently at the end of March – two games before the close of the season – when the volleyball players of TSG Solingen secured the championship title for the northern second division. Congratulations on this huge achievement!

The synchronised swimmers of TSV Aufderhöhe, who we also sponsor, are constantly celebrating, too. The team appeared yet again at the 20th Solingen Sports Gala on 20 February. The gala celebrates the city’s best-loved athletes, as voted for by readers of the local newspaper, the Solinger Tageblatt. Pauline Paffrath, star of the club and a member of the German national youth squad took second place in the “Female athlete of the year” category. What’s more, the German youth squad, consisting of Paffrath and Sarah Hähnel, were given a special honorary award that the city presents to its most cherished sportspeople.

BBS Technik in Cloppenburg can now print its very own three-dimensional objects, such as a miniature Statue of Liberty. Students from Class FSM 2-1 developed a fully functional 3D printer on their own in just six months. The biggest challenges included finding the right materials for the fused deposition modelling (FDM), an additive manufacturing method that involves using a nozzle to apply thin layers of a material that subsequently hardens. The team decided to use a thermoplastic called PLA, which becomes soft and malleable when heated, so that it can be ejected from the printer head as a thin thread.

Expertise and the right technology

Programming the control system for the printer was an even bigger challenge, which Thomas Gruslak took on. Sensors are selected and actuators regulated by an Arduino microcontroller that is programmed with firmware specially adapted for the printer. This control system can be used to reliably execute the preprepared G-code of a component.

The students built the housing of the printer with Line 8 profiles from our MB Building Kit System. The profiles provide the necessary stability while the exceptional versatility of the system meant the students were free to design and build their printer as they wished. Thanks to the use of plexiglass panels, the workings of the printer can be seen in action on three sides. The team also installed a camera on the upper frame that can transmit pictures of the printing process to any monitor. As a result, all of the almost 300 people who attended the presentation were able to watch the production process as it happened.

Huge personal commitment

The project was kicked off in September 2015, starting a period of very hard work. The team took on a huge task in designing the printer, selecting the right components and developing a control system. That meant that besides their work and study, the students also had to invest a lot of their free time in the project in order to turn their theoretical design into a working model. It was the extraordinary ambition and motivation of the team that made this project possible.

When the project was exhibited at BBS, the professional and lively presentation given by Bernd Möddeken, Jan-Philipp Wilke, Michael Kühling, Thomas Gruslak and Christoph Hespe was met with enthusiastic applause from the 300 students and teachers in the audience. “The fact that the printer is fully functional and that we’ve managed to impress our fellow students makes all the hard work of the past few months worthwhile,” says Hespe. He and his colleagues are due to complete their studies as state-certified technicians soon and will then be taking their skills to future employers.

Training for teachers at vocational colleges

We don’t just get involved in specific projects. In October 2015, nine metalworking and mechatronics teachers from vocational colleges in Lower Saxony took part in a training course at our Siek branch in Hamburg. The course focused on the production of assemblies using modular aluminium profile systems. The teachers used their new-found know-how to develop educational materials that will help them cover the topic with their students in a practical, hands-on way. The pilot project proved very popular and is being repeated this year.

It took almost seven years to build the gigantic skyscraper, at an estimated cost of between USD 1.5 and 2.4 billion. Located in the heart of Pudong, Shanghai’s financial and economic centre, the Shanghai Tower is in good company, surrounded as it is by the Jim Mao Tower and the Shanghai World Financial Center, known affectionately to the locals as the “bottle opener” due to its unusual shape. However, don’t be deceived by the dense concentration of skyscrapers – the natural conditions in Shanghai pose significant challenges for engineers. Earthquakes and storms cause strong vibrations and compensating for those calls for great skill. But that is precisely where the profiles in our MB Building Kit System come in.

Think big!

It isn’t just the height of the Shanghai Tower that makes a lasting impression. The architectural concept behind the building was the creation of a vertical “city within a city” comprising nine sections, each made up of 12 to 15 floors. A dazzling range of boutiques, shops, gardens, conference and office rooms, and hotels awaits visitors, spread over a floor area of 380,000 m². A total of 128 floors are interconnected by 149 lifts, three of which are the fastest in the world, notching up a travel speed of 65 km/h.

The most visually striking aspect of the building is its spiral shape, but that isn’t just a bit of fun, it is highly effective in a number of ways. The final shape of the Shanghai Tower is based on a series of wind tunnel tests. By factoring the test results into their design, the architects were able to lower effective wind loading by 24 percent. What’s more, this special, stripped-down architecture helped to reduce costs by USD 58 million. But that’s not all – thanks to the spiral design, the building collects rainwater to be used in heating and air conditioning systems.

Reaching for the skies with aluminium 

However, it isn’t just the shape of the building that helps it withstand the tough conditions in Shanghai – there is also a 1000 metric ton weight located between the 125th and 126th floors. The weight is suspended from 12 steel cables so that it can oscillate when subjected to vibrations. Underneath the weight are plates of pure copper that are fastened to the reinforced concrete floor using item profiles. Huge permanent magnets on the weight help to induce Eddy currents in the copper plates, thereby generating a magnetic field that works in the opposite direction to the weight to generate a contactless braking effect – even during a power failure. Thanks to the principle of the Eddy current brake, the Shanghai Tower is largely resistant to external vibrations.

Building this solution with steel supports was not an option, because these would have been permanently subject to attraction. Unlike iron, aluminium is paramagnetic. The holding force of the profiles ensures the plates can withstand the enormous force of attraction from the magnets for the long term. In fact, the magnets are powerful enough to lift a 300-metric-ton aircraft. However, the robust aluminium profiles stop the magnets and copper plates from coming into contact and thus maintain the braking effect.

The low weight of the profiles also proved to be a crucial advantage, as they had to be lifted to a height of 600 metres by a tower crane then carried by hand down seven floors. Had steel supports been used, it would have taken more than three times as many construction workers to move them into position. What’s more, no additional tools such as cranes or lifting platforms were required when fixing the profiles in place. Nevertheless, the aluminium design boasts the same strength as 304 stainless steel and even Q235A steel.

Why are trade fairs still one of the most popular marketing tools? And how exactly do we go about planning a trade fair?

For us, taking part in trade fairs is an indispensable way of showing customers just how diverse the item product world is. Everywhere you look at a fair there are fascinating and encouraging meetings and discussions going on. And that’s why we take part in so many of them all around the world every year. Since one of those fairs (LogiMAT, 8 – 10 March) has just drawn to a close, we thought now was a good time to give you a behind-the-scenes look at how companies can make the most of a trade fair. Our four-person core trade fair organisation team is very generously giving us unfettered access to find out what their day-to-day work involves.

Preparing well ahead

So how long does it actually take to prepare for a fair? Although the time it takes to prepare varies from one fair to another, work usually gets under way 9 to 12 months beforehand, once participation has been confirmed. Without accommodation, the fair won’t happen, so the first thing to do is book rooms for the trade fair team. A kick-off meeting is scheduled for three to four months before the start of the fair and all the relevant in-house staff are invited to attend.

That includes colleagues from product marketing and development. “A number of issues are discussed at the meeting, such as what we want to exhibit at the fair and whether there should be any special promotions. After that, things get a lot more concrete and focused. Of course, the closer we get to the date, the more work there is to do,” explains Petra. She is responsible for coordinating all marketing activities related to the trade fair – invitation mailings, press releases and much more besides.

A logistical master class

Once everything has been decided, all the materials have to be transported safely to the venue. We almost always work with a shipping company that will look after most of the transport tasks associated with the fair. When it comes to big trade fairs, like Motek, two special vehicles are put to use. We have sponsored the tarpaulins on the trailers, which are white and branded with the item logo. “When the trucks arrive at the exhibition centre, everybody knows that item is there,” says Jens, one of our trade fair planners. His job is to look after all the technical aspects, reserve the stand and communicate with partners.

Our roadshow is also sometimes promoted at trade fairs. As there is usually an MB or D30 presentation at our stands, customers are often recommended to take advantage of this option. “It can definitely be worthwhile having item come along to your company in person. If a customer has a problem that is best sorted out on site, we often use the roadshow to do just that. But it’s another team, usually from the LPS or MB sections, that takes care of that,” explains Jens.

Setting up and finishing touches

An external service provider builds the stand for us in the hall. They lay the (double) floor and install the electrics and overhead rigging. This is where Niko gets involved, along with a colleague from sample building. They are responsible for the finishing touches – putting the exhibits in place, making sure everything is on-theme and, last but not least, checking that all the technical elements are in working order. If they hit a problem, they have to find a solution with the stand builders quickly.

The next step is where the stand personnel come into play and, if the fair is going to be a success, they need to be a committed team. There are customer advisers, product managers and of course (international) sales representatives. The vast majority of them will come from the local item offices. “If we have a trade fair in Stuttgart, the team will come from the regional centre for southwest Germany, but if we’re in Hamburg the personnel will come direct from Hamburg, it’s as simple as that,” says Kathrin. She is responsible for helping to organise the trade fair in advance and coordinating it on site.

Trade fair organisation par excellence

We always make every effort to put on something very special and creative. Entertainment is also particularly important at trade fairs. For example, a “Looping Louie” built from our products was very well received at Motek 2015. We’ve also built an air hockey table from our profiles before.

Why go to all that effort? Easy – a fair incorporates a whole range of elements that are extremely valuable for marketing, sales and development. Firstly, we want to make more people aware of our brand – that’s classic marketing in action. For the sales team, it’s customer care that comes first. Our existing customers who regularly visit trade fairs will seek out the sales contact they know. Another job for the sales team is to grab the attention of visitors who aren’t yet familiar with the company, or might only be aware of certain aspects of its activities.

“Naturally, that can relate to specific areas such as ergonomics or lean production. It’s not unusual for someone to think: ‘Ah, I see, they offer the kind of system we can use, too!’,” explains Jens. All of that can be assessed afterwards, helping us gauge how well the fair went. The contacts that are made (leads) are recorded digitally so that they can be managed efficiently. Finally, for our colleagues in development, a leading fair like Motek is the perfect opportunity to present innovations and find out what everybody else is doing – what our market peers are pursuing and what trends are emerging.

Due to our participation in the soapbox race staged by the Düsseldorf public utility companies last summer (as reported in our article “Lean greased lightning on the banks of the Rhine”), we were asked last week whether we would like to help publicise the campaign. As the details were made clear, we were astounded – the plan was to hold a push-along race during the second interval of the ice hockey derby between DEG and the Krefeld Penguins.

Aluminium hits the ice

We jumped at the chance! To prepare for the upcoming race, some minor modifications were made to our soapbox, which had been designed in-house and built using item D30 profiles. Instead of conventional wheels, we took four skids with us when we headed off to Düsseldorf.

Up until the interval, the item team was able to watch a thrilling ice hockey match that ended in a narrow defeat for DEG. With no goals scored in the regular match or overtime, it was Krefeld’s Henrik Eriksson who scored the deciding goal in the penalty shootout and secured a victory for KEV.

Crunch time

As around 12,000 spectators in the ISS Dome looked on, we also went out onto the ice for a thrilling contest against the green soapbox of the Düsseldorf public utility companies. A mother-and-daughter team from Düsseldorf went up against one of our product managers and his son. Although we hoped that converting our soapbox into a D30 slide on skids would give us the edge, the photo finish showed that we were beaten by just a few centimetres.

But the item racing team will not be discouraged! Our colleagues in the Development and Industrial Design departments are going to carry on working on our soapbox to make sure the next time it takes to the race track it wins more than just hearts.

Having recently looked at a classic aspect of ergonomics, namely sitting, we thought we’d close our summary on ergonomics at industrial work benches by turning our attention to a number of aspects that, unfortunately, are often overlooked. The most important of these are modularity, the handling area and, last but not least, design. However, we’re also going to take another quick look at lighting, albeit from a different viewpoint.

Modularity and the zones of the handling area

In industry, no matter how carefully you plan a work bench, it will never really be finalised if it is being used properly. There are always going to be new needs that require flexible modifications. This is where a modular building kit system really pays off. For example, operators often find that they’ve got nowhere to put something down, but they can sort that out in no time by adding an extra shelf. What’s more, when using a building kit system, it’s just as easy to remove the shelf again later on.

When designing an industrial work bench, it’s always important to take into account the handling area, too. Directly in front of the operator is the two-handed zone, where the process is actually carried out. The one-handed zone, meanwhile, is the best place to position materials and tools that are in frequent use, because workers can reach everything with ease, without having to turn their body. These handling area zones are different for everyone, so it’s important that every worker can arrange material supply and picking systems to suit their own specific needs. Pivot arms are an ideal option for positioning tools in the one-handed zone. They can be fitted with trays (such as Toolboards) as well as parts containers, hooks and holders for stowing tools where they can be easily accessed.

The role of lighting at the industrial work bench

Unlike lighting at an office workstation, where employees are normally all carrying out very similar tasks, the lighting at an industrial work bench has to be tailored precisely to the process that is being conducted there. It is particularly important that the lighting is directed at the working surface so as to ensure optimum effect. Less-than-optimum lighting conditions don’t just affect the concentration and performance of employees, they also force them to deviate from the ideal position as they try to get a better view, thereby taking all the risks that come with poor posture. This shows just how closely interlinked all the various aspects of ergonomics are.

You can find out more about lighting at the work bench in our special article on the subject.

Design also contributes to ergonomics

While we’re talking about how things look at the work bench, it’s worth pointing out that studies have shown workers rate chairs as more comfortable when they like the look of them. However, it is important to point out that this effect declines over time – the longer an employee is sitting in a chair, the more important its physical comfort becomes. Nonetheless, design has a tangible effect on how comfortable employees feel. Moreover, that doesn’t just apply to chairs, it is also true of the entire industrial work bench.

Employees working in an environment that they actively like are more motivated to keep the working surface clean and tidy. On top of that, structured visual design and functional design language make it much easier to grasp working processes. High-end design also offers companies an elegant means of projecting an image – both internally and to the outside world. One thing leads on to another. In fact, that is a very neat way to sum up the holistic approach that is intrinsic to ergonomics.

After looking at the topic of lighting last week, we are now turning our attention to ergonomic sitting practices in industrial environments. There are two sides to this story. The first is the simple fact that people are not designed to spend long periods of time sitting down. Although our bodies can withstand a fair amount of strain, they will sooner or later fight back against continuous pressures. And, when a work bench has not been adapted for the anatomy of the human body, those stresses and strains are very high and intensive over time.

This leads us on to the second side of the story – sitting practices should be designed to be as comfortable as possible for employees and help them maximise their efficiency. 

Skilfully avoid unnecessary strain

Spending hours and hours at work in one and the same posture quickly takes its toll, often resulting in tension, if not pain. Wherever processes allow, it makes sense to change between a sitting and standing posture. A height-adjustable work bench offers particularly good opportunities to do just that. It may sound odd, but it was only 250 years ago that people first started spending long periods of time sitting down. And that is precisely why our bodies are fundamentally unaccustomed to this position. From an ergonomic perspective, when an employee has been working for a long time in a seated position, it is a good idea for him or her to switch to a standing position. This takes a great deal of strain off the back. The ideal ratio is 80 percent dynamic sitting to 20 percent standing.

Ergonomic industrial chairs

Sitting is unavoidable in most activities and that’s why it is essential that chairs follow ergonomic principles. When selecting a chair for an industrial environment, there are several points that should be considered. For example, the upholstery should be robust so that it can be cleaned down as necessary and withstand scuffs, scrapes and rough handling. The most important factor, however, is adjustability. Height adjustment comes first – when seated with your feet flat on the floor, your legs should bend at an angle of just over 90 degrees. To ensure comfortable support under the thighs, the seat should therefore be inclined forward slightly.

This means you can sit comfortably without restricting the blood flow in your legs. Ideally, the back rest should also incorporate a lumbar support. The lumbar region is the area of the spinal column that bends toward the stomach. This is the normal position of the lumbar region. However, if the surrounding muscles are weak, the spine can start to curve in the opposite direction (kyphosis).

Ergonomic sitting and relieving strain on the spinal column

Lumbar supports are integrated into the back rests of work chairs to actively counteract the poor posture associated wtih kyphosis. The back rest should include lumbar support at the correct height for the user’s lower back, a function that is extremely important to ensure an ergonomic sitting posture. 

A reclining tilt mechanism in the back rest that includes tension control enables dynamic sitting, which also better nourishes the spinal joints. Tilting the seat forward slightly by five degrees ensures that your pelvis is angled, which encourages an upright sitting position. Chairs are at least as important in industrial environments as they are in the office. As a consequence, they should always satisfy current ergonomic standards if they are to support efficient and healthy working practices.

LED lighting has long been indispensable to industrial production. A service life of up to 50,000 operating hours, outstanding performance and low energy consumption are benefits that speak for themselves. It is also ideal for use with work bench systems. At the same time, ergonomics, health and safety and productivity all dictate that lighting must be designed to eliminate strain on workers’ eyes, and therefore their concentration. By following a few simple rules, companies can enjoy all the efficiency benefits of LED technology without the potential risks.

Colour temperature and homogeneous lighting

The light colour of an industrial LED lamp is incredibly important, as it can have a huge influence on employee performance and motivation. The following principles should be taken into account when considering light colour: Cold white light has a stimulating effect on the human organism, while warm white light is more calming.

Industrial guidelines have been developed accordingly. For example, a light colour of 4000 kelvin is recommended for an industrial environment such as an assembly operator’s work bench. This value lies between the classic, warm white lighting that we know from filament lamps (2500 to 2700 kelvin) and normal daylight (5800 to 6500 kelvin).

A moderate colour temperature like this supports fatigue-free working practices, puts less strain on employees and helps to reduce error rates – making the workforce altogether much more productive.

Multiple shadows

Multiple shadows, i.e. when a number of shadows overlap each other, also put a strain on the eyes that shouldn’t be underestimated. Let’s imagine a less-than-optimum lighting scenario, one that uses LED technology but in the form of individual spotlights. Each of these light emitting diodes produces a very distinct shadow, which puts a great deal of strain on the eyes. Over the course of the working day, this leads to noticeable fatigue effects. By contrast, homogeneous lighting with soft shadows, as produced by our LED light fittings, has the exact opposite effect – it relieves strain on the employee’s eyes.

Frequency and luminous intensity of industrial LED light fittings

Many companies are still unsure about what kind of pulse rate a lamp should really have to create a pleasant working atmosphere. From an ergonomic perspective, however, the answer is clear – a flicker-free light should always be used. Even low-frequency flickering that workers won’t even notice still inevitably causes stress, which is why only high-frequency LED lamps should be used. This also eliminates strain, thus significantly boosting quality.

Defined area of lighting

The luminous intensity of an industrial LED light fitting must not be underestimated either. If a work bench is fitted with a dazzling light that is open to the side, personnel will inevitably lose their “adaptation” each time they reach past it to stock up on material. “Adaptation” is the ability of the eye to adjust to the prevailing light intensity or, to put it simply, brightness levels. In other words, each time the eyes are exposed to a different level of brightness, they need to adapt to it. That has an enormous impact on concentration levels, which is why glare must be reduced. Shielding and focussing elements help. Our LED light fittings, for example, use an efficient combination of a diffusor panel and parabolic reflector grid that largely eliminates glare. What’s more, there is more light at the work bench – but only where it is actually needed.

The specialist mechanical engineering market continues to grow steadily – and the wants and needs of customers, partners and suppliers are also changing. Companies need to tackle these challenges head on and ensure they never stand still when it comes to innovation. We have taken this approach from the start and are determined to continue improving the MB Building Kit System, which is why we are always working on research projects. One such project is a collaboration with the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in Chemnitz, Germany.

High-speed impact cutting instead of chip forming

The aim of the collaboration was to find a replacement for chip-forming processes to use on series components. The ideal solution was found to be high-speed impact cutting (HSIC) at a speed of 1 ms-1. During the project, the researchers experimented with creating a hole in a steel profile. A previous study had already shown that the process would both be possible and result in high-quality components. However, quantitative studies revealed a different picture: For example, after just a few cutting procedures, cutting punches with PVD-coated and polished surfaces exhibited pronounced adhesive wear, which lead to abrasion and ultimately the breakage of the test tools.

As a result, damage was observed to the cutting edge even before 800 cuts had been performed. Careful scientific investigations into high-speed impact cutting – based on an idea from item engineers – helped resolve this issue. The investigations produced the following conclusions: When the punch penetrates into the sheet material by more than 10 to 50 percent of the sheet thickness, the cut-out section is completely separated from the surrounding area due to the concentration of energy and the “adiabatic effect”, which produces shear bands on a micro scale.

Using HSIC to combat wear

Two conclusions were drawn from this research work. To avoid damage such as this, the shape must first be incised until complete material separation is achieved and then, in a second stage, the separated contour must be ejected by a second punch with a narrower contour. All subsequent investigations were based on this approach and all were successful. Wear was greatly reduced. Despite carrying out several thousand cutting operations, the punch (standard punch, not coated or polished) exhibited only the normal traces of wear associated with conventional processes. The process, which is now patent protected, was also proven to be suitable for use in series production.

The research findings were then used in a collaboration with a renowned plant manufacturer to develop a drive module based on HSIC. This module is designed to ensure the process can be integrated into conventional die cutting technology and state-of-the-art production plants. Our engineers and the specialists from the IWU are currently testing whether this method can also be adopted in other circumstances and for other requirements. It is exciting to think what impact this new technique could have.

Only last week, we emphasised just how important lean principles are for intralogistics. Indeed, there are few other sectors where it is so important to pursue efficiency consistently and at every level. And that is one very good reason to take another look at the special circumstances and continue our journey – with the FIFO method. This method is all about safeguarding material quality, and specifically in storage facilities. If parts are held in storage for too long, numerous problems can arise that do not occur during normal storage, even over long periods of time. This is precisely where the FIFO storage technique comes into play.

What FIFO means

FIFO is an acronym and stands for “first in, first out”. At first glance, the FIFO method seems simple – all the parts that are ordered first are also the first to be taken out of storage and put to use. It is basically no different from the principle that supermarkets use for stacking their shelves. The FIFO process is used in three different instances. Firstly, when one production station works faster than the next one downstream. Secondly, when it is not possible to interlink individual production stages due to technological differences between the processes. And, thirdly, when products are required for several stations.

In all three instances, FIFO defines the sequence of the material flow and a maximum stock level between consecutive processes. It is so important because, when problems are identified, it is easier to trace them back to the place and time of origin and because a predefined maximum stock level will not be exceeded and a fixed sequence is maintained for consumption. Related, but very different systems include LIFO and HIFO. In LIFO (last in, first out) the stored elements are removed in reverse order. Of course, that only makes sense if the relevant parts do not lose value as a result of being in storage. In HIFO (highest in, first out), however, the material that has the highest value is the first to be used.

Using FIFO to tackle material wastage

The principles and concepts of lean production are clear: Material waste of any type is completely contrary to the very core of the Japanese efficiency philosophy. Accordingly, the idea of holding material in storage for as short a period of time as possible fits perfectly with the lean concept. Ultimately, there is no way to guarantee that material will not age, corrode or even get damaged. What’s more, when using a “classic” or even random approach to storage, personnel can’t even see whether parts towards the back are showing signs of these changes. When applying FIFO, issues like these are consigned to the past.

Diving into FIFO

Companies that want to adopt the FIFO process need state-of-the-art material supply systems that will ensure the new parts can be removed easily in line with FIFO principles. Flow racks that are filled from the rear and emptied from the front are ideal. Our tried-and-tested FIFO transport trolleys offer an excellent example of this process in action. Mounted on castors, these mobile racks can be rolled right up to the work bench, thus also providing a material supply system that satisfies the very latest ergonomic standards. It also helps avoid the third muda (unnecessary movement).

The relevant transport containers are inserted into the trolley at one side and slide down an incline to the removal side, as per the flow rack principle. When a container is removed from the rack, the next one in line slides neatly into place. FIFO racks can also be fitted out with practical Kanban roller conveyors, so that fill levels can be identified at a glance and the rack can be restocked with material in good time.

Lean production helps to significantly improve efficiency by cutting out waste. The 7 Muda – the types of waste that the lean philosophy seeks to tackle – also include high stock levels. The just-in-time method is an approach that deals perfectly with this problem by ensuring that suppliers receive orders for only what is actually needed. That might sound banal, but it can also help to cut costs significantly when successfully implemented. The just-in-time method is now a firm fixture of the automotive and aerospace industries. The text below offers an introduction to this highly promising logistics concept.

How just-in-time works

Just-in-time (JIT) means what it says – that materials are available when they are actually needed. In other words, a manufacturing company will get materials from its supplier only when it requires them. Since the process is geared toward the company’s order book, just-in-time production is also sometimes referred to as “demand-flow manufacturing”. The system brings a range of benefits and can significantly lower costs associated with personnel, storage and transport. Capital tie-up costs are also reduced. Ultimately, storage always ties up capital that could be invested usefully elsewhere.

What’s more, flexibility is significantly improved, which supports better service, as customer requirements can be met more quickly. Under certain circumstances, small buffers and/or waiting times can occur, though there is no conventional stockkeeping as such. The same applies to the intralogistics aspect of just-in-time, which is managed with Kanban (cards) that represent an order for materials that is submitted to the upstream station (pull principle). Today, an IT-based version of this system, known as e-Kanban, is growing in popularity. By visually mapping processes, it gives users a good opportunity to identify ways that systems can be optimised.

The prerequisites and risks of JIT logistics

The aforementioned benefits of just-in-time make the system an interesting option for industrial production. However, the basic prerequisites associated with it should not be overlooked. Not every production system is compatible with this kind of approach. Indeed, it only really works when large volumes of material are involved, otherwise it is difficult to justify the logistics outlay that comes with JIT. Moreover, JIT requires outstanding infrastructure both inside and outside the plant and covers the entire supply chain.

On top of that, the system places a great deal of responsibility on suppliers. It goes without saying that they must be flexible when it comes to logistics. There are also numerous external factors that have an impact, such as difficult climatic conditions and traffic levels, which can easily throw the entire production system into disarray. All this needs to be taken into account at all times. However, there is also an opportunity to establish a completely trusting relationship between supplier and manufacturer that can benefit both parties enormously. What’s more, the global success of the just-in-time method speaks for itself.

As the end of the year draws closer, crowds head for the Christmas markets and of course the mulled wine starts to flow freely. But how about trying a tasty fruit juice instead? We want to throw our weight behind that option and so here is another blog entry on the fantastic “Juice on Wheels”. The mobile juice bar makes its tasty orange juice using an entirely environmentally friendly process. However, the bar’s founder, Peter Blesgraaf, went more than one extra mile to show how seriously he takes his commitment to the environment when he took his very special vehicle all the way from the Netherlands to a demonstration at the Paris Climate Change Conference (30 November to 11 December).

A long journey full of great experiences

Blesgraaf was joined on his journey to Paris by five companions. Together they travelled from Nijmegen through Hasselt, Charleroi, Saint-Quentin and Senlis before finally reaching the French capital. While his fellow travellers rode normal bikes, Blasgraaf was of course on his trusty cargo trike. The mobile orange juice bar is built largely using technology from our Profile Tube System D30.

The riders enjoyed plenty of memorable encounters as they made their way to the conference. For example, just before they reached Saint-Quentin, the “Juice on Wheels” boss met a friendly organic baker who was out on the road and stopped to offer the cyclists bread and chocolate as soon as he spotted the unusual vehicle. The baker was very sympathetic towards their climate quest, and had only recently supplied food for “The Climate Miles” campaign. In a display of exceptional hospitality, he also provided a warm place to spend the night.

Moving moments in Paris

The journey was organised as part of a campaign by the “Tour de Climat” group, which aimed to get as many residents of Nijmegen as possible to the Paris Climate Change Conference. The high point of the entire campaign was to be joining the huge “La Marche pour le Climate” demonstration on 29 November. However, given the circumstances, it was not possible to stage such an event in Paris. Nonetheless, the alternative proved to be no less effective, with participants each donating a pair of shoes that would continue the “journey” to a better world on their behalf and be passed on to people in need.

So did everyone really hand over shoes? Not quite, Peter Blasgraaf didn’t have any spare footwear with him. Instead, he donated his spare tyres, which are sure to give their future owner plenty of service. He was visibly moved by the atmosphere in the city: “I had hundreds of spontaneous and inspiring discussions. The people in Paris showed huge commitment to the issues of peace and climate change.” Blasgraf also met André Kuipers there, who is by far the most famous astronaut to have come out of the Netherlands. He has been to space twice and holds the record in western Europe for the longest stay in space, at 192 days.

Having already looked at several lean methods in detail, we are now turning to a similar method for optimising in-house production. However, instead of focussing on throughput time, this method aims to improve quality. Six Sigma is an extremely successful means of analysing and enhancing process quality. Based on a statistical methodology, it can help companies save more than 100,000 euros.

What Six Sigma means

“Sigma” (σ) is the 18th letter of the Greek alphabet. In 1860, Francis Garlton (1822-1911) introduced it as a symbol in the mathematical discipline of statistics. It stands for a variable’s dispersion around its average, or standard deviation. That, in turn, can be traced back to the famous German mathematician Carl Friedrich Gauss (1777-1855).

A six sigma process is one where 99.9996 percent of the elements are error free. In other words, if there are a million opportunities for an error to occur, there will only be – in statistical terms – 3.4 errors.  This number is so low that you could also talk about zero-error production or zero-fault quality. In most companies that have not pursued the corresponding optimisation model, a quality of 3 to 4 sigma is normal, i.e. a success rating of between 93.3 and 99.4 percent. To clarify, if a company has achieved 3 sigma, one million error opportunities will result in 66,807 errors. That leaves a lot of room for improvement.

American-Japanese rivalry

While its predecessor was rolled out in the Japanese shipbuilding industry of the 1970s, the Six Sigma concept was first introduced as such in the USA in 1987. It all started with Motorola. The group was always playing catch-up with its competitors in Japan and it was essential that it found a way to significantly improve product and process quality.

Motorola was inspired by a television division that it used to own and which was now being run by a Japanese company called Mitsushita. The division was more successful than ever before and its televisions were exhibiting 95 percent fewer faults than they did when Motorola was in charge. The new management team had achieved these results by making significant structural changes and applying statistical methods.

Six Sigma finally became popular thanks to General Electric, whose CEO at the time, Jack Welch, declared it the number 1 quality maxim. According to official figures, the method produced two billion US dollars in savings within three years. The Six Sigma concept spread around the world. 

Six Sigma: Allocation of roles and hierarchy

Only specially trained employees are deployed in Six Sigma projects. Their roles are described based on the ranking system used in Japanese martial arts such as Karate (i.e. belts) and the hierarchy is governed on a similarly strict basis. We are only going to look at three positions here:

The highest rank is that of Master Black Belt, an individual who has sufficient experience and expertise to train other employees. Green Belts will usually be from middle management level, report directly to the Black Belt and run their own projects and teams. In Japan, companies began to combine Six Sigma with the lean philosophy to get the best of both process optimisation approaches. Combined approaches such as these are given names such as Lean Sigma and Lean Six Sigma.

The DMAIC cycle

The DMAIC cycle is the basis for every Six Sigma project and comprises the following steps – define, measure, analyse, improve and control. It makes existing processes measurable so that they can be continuously improved in order to satisfy customers. These processes are divided into the smallest worksteps possible, which results in numerous individual elements for boosting value creation. These elements are adjusted in relation to both upstream and downstream processes. 

The define phase involves identifying and documenting the processes that are to be optimised, the associated difficulties and how the process is to be optimised as part of the Six Sigma project. Next is the measure phase, which is when numbers, facts and figures are recorded for the process under scrutiny. This data is then analysed and evaluated during the analysis phase. The results of that phase are used in the subsequent improve phase to develop measures for effectively rectifying the error causes that have been identified.

During the following control phase, the company monitors the entire process based on statistical means. There are two different intentions behind this – firstly, documenting the functionality and sustainability of the process and, secondly, finding new bases for future Six Sigma projects. The latter point slots neatly into the continuous improvement process (CIP).

So now is a good time to take a look back over a success story and look ahead at the highlights yet to come. Stephan Koch, a product manager at item, is the ideal person to talk to about just that. In this interview, he offers the benefit of his many years of experience at the company.

The rapid growth of item is closely linked to the development of the MB Building Kit System in the early 1980s. What were the most important factors back then?

item was originally a design office for specialist mechanical engineering and production plants that focussed on the challenges its customers faced in assembly and grinding technology. It quickly became apparent that the steel construction methods in use at the time came with considerable risks. Complex and costly processes such as welding, milling, grinding, cleaning and coating, high levels of investment in machinery, high personnel costs and long assembly and delivery times all tied up a lot of capital.

The MB Building Kit System provided the ideal solution. Its unique selling points still apply today: There is no need for welding, milling, grinding, cleaning or coating. Only minimal investment in machinery is required and there is no need for personnel with special training for specific machinery, either. It is much easier to design modular assemblies that can be modified at any time.

Why is quality often more important than the price of components in this part of the mechanical engineering sector?

Quality is no longer defined simply in terms of how durable and resilient a product is – like some good old branded washing machine your mother might hand down to you. Today, in industry and in the mechanical engineering sector, all the qualities of a product are taken into consideration – from the system as a whole to the associated processes.

In recent times, in particular, it has become increasingly important for industrial companies to be lean and not tie up capital unnecessarily. One aspect of that is that companies shouldn’t produce or store any more than is necessary. Or, to put it simply, companies should only produce something once it has been ordered.

It is not just that individual products have to be durable and resilient – the whole system behind them has to be easy to understand and versatile at the same time. However, the most important factor today is a high level of service. That includes personalised customer advice, technical and design support, customisation options and damage-free delivery within 48 hours.

What would you say is the most important attribute of the profile technology from item?

Without a doubt, the fact that it is innovative. Twice a year, item presents new products that give users even more opportunities to optimise and customise their work. At the same time, they can make the most of all the benefits offered by a building kit system. More than 1000 individual sales articles have been launched since 2010. That is more than 160 products a year that have been introduced to help our customers work faster and find more effective solutions for complex challenges.

The products are developed in close collaboration with customers, who describe their challenges to us. Four products in particular deserve a special mention. First is the highly stable profile tube system for CIP workshops, which is used for lean manufacturing processes. Second is the cutting-edge XMS building kit system with an integrated seal system and cable conduits, which is used to produce automation cells and machines. Third and fourth are the Installation Column and the Work Bench System, which can be custom configured and combined and interlinked with any of the elements in the building kit system.

Quality, service and time savings

What would you say is the essence of item?

It is that we provide everything from a single source and to a dependable quality standard. All the products that item offers its customers have gone through exhaustive testing during the prototype engineering phase. We incorporate safety factors that are geared to the product and the needs of users. That means we can ensure maximum durability and resistance.

A building kit system is more than the sum of its parts. It only works when everything comes from the same source and is mutually compatible. It also has to be available at short notice. The more that something can be procured from the same source, the better. Delivery times can be coordinated and planned faster and more easily and the number of contacts kept low.

What makes item so different from other manufacturers?

All the products from our company are 100 % compatible. A lot of our customers appreciate that – particularly when it comes to large, complex structures. There are plenty of manufacturers that boast about being 100 % compatible with item. However, item has never shared the precise dimensions that its profile technology is produced to, nor, more importantly, the tight tolerance zones that it works with. It may well be that these third-party products seem to fit at first, but it is highly doubtful whether they guarantee 100 % stability and functionality.

Has time become a more important factor in recent years?

Time has always been a very important factor in mechanical engineering, whether in relation to milestones that need to be planned or delivery deadlines that have to be met. However, sticking to these deadlines is becoming increasingly important. In many sectors, before assigning an order, customers now specify penalties that will apply if a delivery deadline is missed to a significant degree.

As a result, there is a lot of pressure on manufacturers. Added to this are the ever-changing requirements profiles, which frequently mean that plants need to be modified. Mechanical engineers are having to help customers optimise or convert their production systems on an increasingly regular basis.

How can item support its customers in this regard?

Naturally, with a high standard of delivery reliability. Our state-of-the-art central warehouse makes it easy to manage storage capacities and supports immediate availability thanks to its size. Our widespread, worldwide network of dealers and partners also offers added security. Dealers and partners can take action immediately.

This system ensures rapid delivery. We offer and guarantee 48-hour dispatch for individual components and products in Germany. What’s more, we are also building a new dispatch centre. We know what our customers need and act accordingly. item has a dense network of customer advisers and specialists who are always on hand to offer customers their support, whether face-to-face on-site or over the telephone.

We have also created the item pluspartner network for dealing with complex challenges and developing targeted process solutions. This network is made up of companies that specialise in industry-specific solutions from a whole range of sectors, from work bench systems and assembly and inspection facilities through to cleanrooms and guards and enclosures. Customers benefit from wide-ranging process expertise and imaginative solutions.

Industrial production is always subject to fluctuations – in both directions. The Japanese Heijunka method represents an ideal tool for smoothing out the flow of production.

There are numerous lean production concepts that have become commonplace in western Europe, such as the 7 Muda and the continuous improvement process (CIP). The Heijunka concept, however, is much less well known, which is regrettable, because it is one of the building blocks of the Toyota Production System (TPS). What’s more, a lot of other lean ideas are based on it, such as the pull principle.

Heijunka is about keeping production at a consistent level, so that external fluctuations have no impact. It also prevents the bullwhip effect, which is when minor demand fluctuations in a process result in spiralling demand fluctuations in upstream processes. In the worst-case scenario, this effect can culminate in material bottlenecks that interfere with the Kanban pull systems so popular in industry.

Mura = imbalance

To properly understand Heijunka, it is important to know exactly how the bullwhip effect is inhibited. After Muri (excess strain) and Muda, Mura is the third component in the Japanese notion of waste (3M model). Translated from the Japanese, it means “unevenness”, “irregularity” or “lack of uniformity”. In other words, it describes the absence of balance in the production workflow, which leaves production completely exposed to common market fluctuations. This can in turn lead to both excessive strain and debilitating waits due to material bottlenecks. Mura can also therefore be seen as a combination of Muda and Muri.

Heijunka: Counteracting imbalance

The principle of Heijunka provides the perfect answer to Mura – it is about levelling and smoothing production. Heijunka ensures that the material flow is harmonised in terms of volumes and mix. However, ensuring uniformity is not the only aim. Ideally, the same quantity of products should be produced at all times.

So how does Heijunka differ from conventional production levelling and smoothing? Standard levelling involves dividing the products that are to be manufactured into day rates. By contrast, the aim of Heijunka is to lower batch sizes towards the ideal of a batch size of 1. To achieve this goal in a gradual process, setup times need to be lowered.

However, that doesn’t mean that each variant of a product also ought to be manufactured at least once a day. That is not possible. Heijunka helps to reduce batch sizes and therefore increases the number of setup processes that are required. To prevent unnecessary waiting times, setup times have to be minimised (e.g. by applying the SMED methodology). Heijunka is particularly ideal for production processes with a multi-stage make-up.

Picking and Heijunka boxes 

Heijunka also requires a high degree of efficiency in material supply and picking. Numerous parts groups have to be available simultaneously – without possibilities for substitution or conversion. As a result, there are a lot of tools at the work bench that need to be stowed in a space-saving manner and in line with the rules of ergonomics. Naturally, the same applies to the arrangement of machinery.

In Heijunka, everything has to be organised so that products run through the production process without having to be held in temporary storage along the way. A Heijunka box is the ideal planning and visualisation tool for the entire process. It is a schedule in which products are arranged vertically and times are marked horizontally. Each individual pigeon hole or cell in the box is a time slot and cards are used to allocate these slots to the relevant products.

Whether as students or teachers, we never really stop learning, which is why nine metalworking and mechatronics teachers from vocational schools in Lower Saxony came along to our Hamburg branch in Siek in mid-October. The training course focused on the production of assemblies using modular aluminium profile systems. The teachers used their new-found know-how to develop educational materials that will help them cover the topic with their students in a hands-on way.

A new type of cooperation

While training courses on the latest mechanical engineering issues are part and parcel of our established service portfolio, a training course for school teachers was a real first. It all started with an enquiry from a teacher, Dirk Grosser. Besides teaching at vocational school BBS II Gifhorn, he is also a specialist in metalworking for the Lower Saxony regional schools authority and works for the Lower Saxony Regional Institute for Educational Quality Enhancement (NLQ), which offers numerous courses for teachers. It didn’t take long for a collaboration to be set in motion.

The event was opened up to applicants at two information days in spring and summer 2015, and nine enthusiastic teachers secured a place. A few months later, they joined us in Hamburg for the three-day training course. The course kicked off by focussing on the theoretical principles behind the MB Building Kit System and Profile Tube System D30. A range of exercises, presentations and working materials made sure everyone was brought up to speed. However, there was a strong practical element to this day of theoretical study. For example, the teachers had to assemble sample joints from a training sample pack.

Plenty of design freedom

Training sample packs like the one used in the course, which can be regarded as a kind of comprehensive sample pack, contain a kit comprising profiles and fasteners from Line 8 of the MB Building Kit System. In principle, it is a type of test set that can be used to experiment with the key components. The next step was to use the smaller sample pack to practise lesson preparation. At the end of the day, having completed additional exercises on fastening techniques, the trainees had to build a drinks rack using Profile Tube System D30.

The next day of the workshop saw the teachers unleash their creativity. After completing the written “Are you fit?” test and listening to a brief summary, the trainees set to work. Divided into groups of three, they had to set up a project of their own that factored in all the relevant steps – from project engineering and preparation through to compiling a material list and completing final assembly. They had to build a laboratory work bench, an inspection work bench and a transport trolley. The latter had to be designed to store and transport the class sets for the sample packs.

The teachers were able to take away all the projects afterwards, so that they could use them back at their schools. “Of course, it went down extremely well. The participants were particularly pleased that they had so much design freedom,” says Jörg Schiemann from item didactics, the company’s education and training team. He oversaw the entire project and led the first two days of the course himself. On the final day, Dirk Grosser took on the role of course leader and worked with the trainees to consider relevant teaching scenarios and develop educational concepts. It is exciting to think what the teachers will be saying to their classes about their experience. There are definite plans to offer the course again next year and authorities in other regions of Germany have already declared an interest, too.

The final of the 10th ChemCar competition took place at the start of September, during the annual meeting of the Fluid Dynamics and Separation section in Bamberg.

Teams from seven universities across Germany and one from Poland made for a rich and diverse starting line. In other words, conditions were ideal for victory in the ChemCar competition to be snatched by an original concept for a car powered purely by biochemical processes. The team from RWTH Aachen University had our support in more ways than one – not only did we sponsor their team, they also used our aluminium profiles to develop the basic chassis for their vehicle.

Innovative ChemCar concepts

During the ChemCar competition, participating teams exhibit the vehicles they have developed, which feature innovative biochemical drive concepts, and compete against each other in a race. Safety, creativity and reproducibility are the watchwords of the contest, which is organised by “Creative Young Process Engineers” (kreative junge Verfahrensingenieure – kjVI), the Association of German Engineers (VDI-GVC) and the Society for Chemical Engineering and Biotechnology (DECHEMA).

Each team’s concept and the safety of the vehicles is also judged by a panel of sponsors. The team from RWTH Aachen University, which entered under the name “Aixtreme VelociTeam”, had been working on the development and construction of its complex ChemCar concept at the Aachen Chemical Engineering Institute since January of this year. The eight students come from various process and design engineering disciplines on the mechanical engineering course.

Solution for a frequent problem

The biggest incentive for the Aixtreme VelociTeam was to develop a transmission concept that would resolve a problem familiar from previous ChemCar competitions. In recent years, whether because of unevenness or changes in ground conditions, many teams have fallen at the first hurdle by failing to achieve sufficiently high starting torque – meaning they won zero points in the races. The team from Aachen therefore chose to work on a continuously variable transmission (CVT).

When the vehicle is started, the CVT translates the high RPM into high torque. A centrifugal governor then takes over regulation. The ChemCar – dubbed “Lisbeth” – is powered by the catalytic decomposition of hydrogen peroxide, which produces oxygen and thus generates pressure that forces water out of a tank. The water is routed through nozzles to a Pelton turbine that converts the water pressure into rotational energy and transfers the power to the transmission and then ultimately to the tyres.

Hotly contested race

Competing against each other in the ChemCar race were teams from Technische Universität Braunschweig, Hamburg University of Applied Sciences, TU Dortmund University, Clausthal University of Technology, RWTH Aachen University, Münster University of Applied Sciences, Łódź University of Technology (Poland) and Karlsruher Institute of Technology (KIT). The aim was to complete two races, driving a distance between five and 20 metres and carrying an additional weight of up to 30 percent, with both the exact distance and weight selected at random on the day of the competition. The result of the draw was that the vehicles had to cover 8.50 metres with an additional weight of 15 percent. In both attempts, the team that gets closest to the target wins.

In the first heat, RWTH Aachen University’s ChemCar covered 8.18 m to almost reach the target distance and took the lead at first. In the second heat, however, it was the ChemCar from Münster University of Applied Sciences that performed best and got that little bit closer to the finish line. As a result, at the end of round two, the team from Münster were in the lead. Nevertheless, with a more innovative process, outstanding environmental credentials and an impressive safety concept, the team from Aachen won over the judging panel to secure crucial points and snatch victory. Münster University of Applied Sciences took second place, followed by KIT and the team from Poland. This was the second victory in a row for the Aachen students and saw the team led by Marie Fartmann take home 2000 Euros in prize money.

It was 6 September and the big day had arrived. The Miss-Zöpfchen-Lauf race got Solingen moving. In its 9th year, the charity race event saw a large number of runners big and small (Bambini race), Nordic walkers and inline skaters take to the track between Solingen and Wuppertal for a good cause. And a team from item was there, too.

It was the fifth time a team of runners from our company has given it their all in the Miss-Zöpfchen-Lauf race. However, the race is about more than just sporting ambition, it is a great outpouring of community spirit in our home city of Solingen. And when it’s in the name of a good cause, you can count us in. Ultimately, most of the money raised by the event goes towards the lighting on the popular Korkenziehertrasse pathway, which also serves as the route for the race. Ten new lights were only recently installed on the route. Our team of ten had to complete a five kilometre stretch as part of the corporate race.

Two new records and a lot of enthusiasm

It would take more than a bit of autumnal weather to stop the residents of Solingen joining in. In fact, despite the weather, the 9th Miss-Zöpfchen-Lauf set a new record for the number of participants. At 1,400, the total number of entrants of all ages easily overshadowed the previous record of 980 racers. Participant numbers hit the 1,000 mark almost a week before the start date.

Once the event had been opened in fine style by “Em Brass”, Solingen’s first and only marching band, the entrants were off. The inline skaters got things started on Sunday, followed by the half-marathon runners, who had 21.1 kilometres to cover. The half-marathon is particularly popular as a warm-up for the Cologne Marathon in October. Right at the end, at 2.15 p.m., it was time for the corporate race to get under way. With just under 500 runners, it was the best attended race of the day.

The number of participants was also a record for this particular discipline. “I was particularly impressed by the result of the corporate race. Lots of company bosses have realised how important it is to support the pathway,” says Hartmut Lemmer, President of the Solingen Sports Association. Although there had only been a few light showers earlier in the day, the corporate race was drenched with a hefty downpour. That didn’t matter to our team, which didn’t let the conditions stand in their way. Our very own refreshment station at the trackside – built using D30 profiles – kept the runners hydrated.

The story behind the Miss-Zöpfchen-Lauf

 So how did the race event come by the name “Miss-Zöpfchen-Lauf”? It is bound to be an odd name to anyone who isn’t from Solingen. Let’s start at the beginning: Solingen is the centre of the blade industry in German, a tradition that is proudly upheld by its inhabitants. One of the local customs is a beauty contest for the title of Miss Zöpfchen, which is derived from the German word for braids, Zöpfe, and the local dialect term for a small paring knife, Zöppken. Every year, the locals head to the renowned Zöppkesmarkt flea market to see prettiest braids in the city and celebrate Solingen’s proud reputation as the “City of Blades”.

During her tenure as Miss Zöpfchen 2006, Kim Armbrüster turned her attention to the city’s Korkenziehertrasse pathway. The route once connected Wuppertal-Vohwinkel and Solingen by train, and work on it began in April 1886. Although the trains stopped running in 1995, the track, which spirals through the landscape like a corkscrew (Korkenzieher in German), proved to be a big hit with joggers and cyclists, because it doesn’t have any steep gradients.

There was, however, one major downside to the route – it had no electric lighting, and the city couldn’t afford to install any. Following the track early in the morning or in the evenings was not much fun. Armbrüster came up with the idea of holding a charity race to “bring light into the dark”, as she puts it. It didn’t take long for her enthusiasm to spread to family, friends, the city of Solingen and the Solingen Sports Association. The first Miss-Zöpfchen-Lauf race was held the very next year, organised by the charity “Licht für die Trasse” (Light for the Track). Since then, lights have been installed along 7 of the 11 kilometres of pathway, thanks to this unconventional approach.

Lean production and particularly 5S are a combination of concept and technology. And there can be no better example of this than when our Work Bench System was rolled out at Multi-Contact. The end result was that process times were improved by around 70 percent.

Swiss firm Multi-Contact is a global leader in the production of electric plug connectors and contact systems. Its plant in Weil am Rhein specialises in smaller volumes and customer-specific solutions and produces more than 9,000 products on both a semi-automated and manual basis. To optimise its manufacturing processes, the branch opted for three U-shaped lines based on lean principles. Lean Production was put into practice primarily by organising the workplace according to the 5S concept.

Using 5S to tactically boost efficiency

The 5S method is playing a crucial role in the changes being introduced at Multi-Contact. It incorporates five principles for optimising working practices, all of which begin with an “S” in Japanese. They may seem pretty obvious at first glance but, as is so often the case, the devil is in the detail – and in this case the “devil” is waste (“Muda”). 5S comprises the following core concepts:

•    Seiri: Sorting out everything you don’t immediately need
•    Seiton: Arranging and labelling working materials based on ergonomic principles
•    Seiso: Thoroughly cleaning the workplace
•    Seiketsu: Keeping the workplace clean and tidy at all times to prevent disorder

All these points, but particularly the first few, combine to deliver an impressive overall improvement. Indeed, once it had implemented Seiri and sorted out its facilities, Multi-Contact had freed up a great deal of space. Numerous cabinets were removed and replaced with elements that are easier to access. In the past, personnel sat at benches that were up to four metres wide, but today material is conveyed to them from the side and front. The problems associated with having limited freedom of movement have also been consigned to the past, now that Seiton ensures personnel can lay their hands directly on the materials they need. The 5S method has helped the company put in place a smooth and seamless workflow.

Employee involvement and value-stream mapping  

Another important factor was the decision to arrange the working cells in a U shape. Personnel work through all the various stations one after the other to manufacture the product in one go. What’s more, the management team at Multi-Contact wanted the production system to make more allowances for different sequences and the different shapes and sizes of operators. Fortunately, comfort and efficiency go hand-in-hand with lean production. However, it was crucial to involve the workforce, and so each and every member of the workforce used a sample bench to establish what their lean work bench should look like.

Another factor in optimising production processes was implementing value-stream mapping. All the various stages in production and in the flow of information were subjected to detailed analysis, with employees playing an important part in this process, too. As a result, the project team was able to establish exactly where value was being created and where Muda – in other words, waste – was being generated. Given the wide range of activities implemented, the 70 percent improvement in process time is no miracle, but rather the result of very focussed efforts.

Last Sunday, the Ecurie Aix team from RWTH Aachen University was competing at the Hockenheimring circuit, in a race that is part of Formula Student. This prestigious competition challenges teams of students to design and build their own racing car and compete against rival teams from other universities in a series of races. However, the teams don’t just gain points for fast times, but for their work as a whole, which includes elements such as design and financial planning. The races are held at some of the best known circuits in the world, such as Silverstone in the UK. And wherever the 80-strong team from Aachen goes, it takes with it elements of its exhibition stand so it can make sure this year’s car is properly presented. We helped out with the development of the stand from the early stages and would like to tell you a little about the background and the team in this blog entry.

The Ecurie Aix team: Racing cars made in Aachen

The Ecurie Aix team: Racing cars made in AachenThe team at RWTH Aachen University was established in 2000 under the name “Ecurie Aix”, which draws on its geographical location in more ways than one. Aachen is less than one hour by car from the legendary Spa-Francorchamps circuit in Belgium, which was also home to the 1950s Formula 1 team “Ecurie Francorchamps”. “Ecurie” simply means racing team, and combining it with “Aix” from “Aix-la Chapelle” (the French name for Aachen) is a neat way of linking the region with the golden age of motor racing. Two years after its founding, the team became one of the first German teams ever to participate in Formula Student when it entered its car “ecurie aix car 1” (eac01).

Every two years after that, the team produced a new car, with students racing on circuits in Birmingham, Detriot and Hockenheim. When it was established as an official club in 2009 its ambitions grew, and since then a new car has been developed every year. In the following year, “ecurie aix car electric 1” (eace01) became the team’s first fully electric racing car. Last year saw another impressive first, as the team chose to enter only an electric vehicle -– the eace03 – having previously entered both conventional and electric vehicles. This year’s eace04 is also based on this cutting-edge technology. And of course, the perfect backdrop for this impressive vehicle is provided by our exhibition stand, which really helps the team stand out from its competitors.

An exhibition stand that breaks with convention

It all started out as a project for the 2014 summer semester, with students at the Chair for Supporting Structures tasked with creating a suitable exhibition stand for eace04. Finally, on 13 June 2014, three short-listed designs were presented to us at our Solingen headquarters. “We received a very warm welcome,” says Tim Both, one of the racing team’s organisers. Stefan Friedrich (Sales, Systems Technology) and Marcus Büser (Sales, Turnkey Solutions) discussed the designs with the Masters students from Aachen. The main aims were to keep the stand light in weight and trim it down to the key elements.

Naturally, the final decision rested with the students. Once they had made their choice, our team headed straight for the university to investigate the technical feasibility of the design in detail. The panels of the winning design are made from a stretch fabric that is clamped in the groove of a Profile 6 with a special leather band. Line 6 has also been used to build the load-carrying frame structure. The contrast between the rear wall and the pedestal produces a striking look, with the background swathed in black fabric while the pedestal is surrounded by a white casing with additional lighting. “The focus should be entirely on the racing car,” explains Both. And that was precisely the effect achieved on 1 June, during the presentation in the university’s AachenMünchener Halle auditorium.

We wish the Ecurie Aix team all the best for all their future endeavours. After races in Silverstone and Hockenheim, the next event is scheduled for 10 to 13 August in Spielberg (Austria). The stand will also have its first outing at a major trade fair when it is unveiled at this year’s International Motor Show (IAA) from 17 to 29 September.

The continuation of our interview with Professor Helmut Abels from Cologne University of Applied Sciences focuses on the consequences of lean production and the continuous improvement process for companies and their employees. There are interesting findings regarding the introduction of lean production outside Japan. You can read the first part, which focuses on practical training for students using lean production building kit systems and the use of tube systems in research and education here.

Kaizen is more than a planning method

Kaizen and the lean philosophy are much more than just additional planning methods. While in a centralised planning system, the individual employee is responsible only for executing sequences, in lean production he or she becomes the driving force.

“The difference between Kaizen and more conventional approaches in industry is that businesses used to try and boost their productivity by investing huge sums without involving their workforce,” explains Professor Abels. “Kaizen works differently because it recognises that progress can be made in small steps. There is also an acknowledgement that steps that didn’t work out can be subsequently corrected and that companies can learn which steps are truly effective and efficient and which ones aren’t.”

CIP – the long road to lean production

At first glance, it can be difficult to see how Kaizen demonstrates any appreciation for employees. At first, when the lean philosophy spread beyond Japan at the outset of its global tour de force, companies largely underestimated the potential they could unlock by involving employees. They often misinterpreted this crucial aspect as nothing more than a suggestion they should take an opinion poll. This was an avoidable diversion that had a detrimental impact on effectiveness.

As a result, lean production was basically introduced twice in many countries, believes Professor Abels: “The first time was in the early 90s, shortly after the book ‘The Machine that changed the World: The Story of Lean Production’ by Womack, Jones and Roos came out. Back then, only the lean methods were applied and important elements were missed – first and foremost the employees! The workforce has to accept and embrace everything involved so that they can help it develop.”

In the continuous development process, employees are at the very heart of industrial production. That is because, firstly, they naturally notice errors before anyone else and, secondly, they are significantly more motivated when they have a role to play in developing the product or innovations. Addressing the essential issue of employee involvement, Professor Abels has the following to say: “Not including the workforce in the development process is a mistake. They are simply more likely to accept something when they’re not just confronted with it – and can see the faults in it straight away.”

Kaizen in practice: The employee as a partner

Professor Abels also points out that sensible productivity increases are accepted by employees, even if many wouldn’t have faith in them right from the start. “I believe everyone is aware that any company has to increase its productivity,” says the Professor, who teaches at the Faculty of Automotive Systems and Production. If employees are involved from the start, the process will “automatically take root better.” That is not just a theory. Numerous studies show clearly that levels of competitiveness have improved significantly in those sectors where the lean philosophy has been put into practice.

“The European production plants of the automotive industry are now at the same level as Toyota,” emphasises Professor Abels. The lean philosophy was developed at the world’s biggest car maker in the 50s. “The Europeans have long since made up for the ground they had lost in the 90s. We can say that, from the perspective of international competition, everyone is at more or less the same level today.” It is no exaggeration to say that lean production has been on a global tour de force.

In-house experience carries lean production forward

Professor Abels uses one example in particular to highlight the strengths of lean production. It starts with what seems like an optimised process – the emphasis being on “seems” – at a work bench at Cologne University of Applied Sciences where a screw drive is prepared. However, putting the screws on the threaded rod only looks easy at first glance. “It’s all a bit awkward,” says Professor Abels, as he demonstrates. However, you only realise that when you are actually working on the parts in question.

That is why the university encourages its up-and-coming engineers and technicians to try everything out for themselves. “These are the things the students have to put right,” says Professor Abels. If the students notice that the containers are too high to allow easy access to the components, they may decide to lower them so that operators can reach everything more easily. When using a second-generation lean production building kit system, individual struts can be moved with ease and without having to completely disassemble the entire frame.

That was the last part of our interview with Professor Abels. However, we will continue to look at the principles and development of the lean philosophy in future.

CIP and the principles of lean production have been the subject of in-depth research and have long since been integral components of courses at higher and further education institutions. However, examining the theory behind lean production methods is not enough on its own. For a two-part article, we asked Professor Helmut Abels from Cologne University of Applied Sciences about the relevant course content and methods. In the first part, we look at the use of lean production building kit systems in research and teaching, while the second part focuses on Kaizen and the lean philosop

Universities get to grips with Kaizen and lean production

Engineering students who want to know how companies keep their production efficient will also have to familiarise themselves with the theory and practice of Kaizen, the continuous improvement process and the seven Muda (types of waste). That is the only way to get to grips with the pros and cons of the various methods and be well equipped for the future.

Forward-looking educational institutions such as Cologne University of Applied Sciences use tube systems to make sure students can get practical experience. What does it feel like to plan a production line and then work on it, too? Do the sequences work as easily as it seemed they would on paper? “The core idea of lean production that we’re establishing here is that we don’t just want to give our students a grounding in theory,” explains Professor Abels from the Faculty of Automotive Systems and Production, “they want to use all their senses to find out how it works and what steps need to be taken to get a lean factory up and running.”

Using tube systems for lean production throughout the entire production process

Students at the university learn how to build a star-shaped production system, for example, with a warehouse located in the centre to supply all the work benches arranged around it. The lean factory at Cologne UAS is ideal for training students in how to build small, effective production units.

That is made possible by our Profile Tube System D30. The entire lean factory is built from this second-generation Lean Production Building Kit System. Professor Abels takes up the story: “We looked at a lot of these tube systems and what we really liked about D30 is that it follows lean principles closely.”

That is not something that can be taken for granted, as the professor explains: “A classic element in our lean studies involves trying to tighten a long screw and then asking the students – ‘When does it start to get lean?’ and ‘When does the value creation start?’ The value creation actually only comes into play with the final tightening. It’s the same with these elements – they’re designed so you can simply insert the tube and give it a half-turn to tighten it quickly.”

Reusable aluminium tubes as a basis

Cologne UAS also wanted a system that would be flexible and satisfy high quality standards over a long service life. Indeed, the components have to be unscrewed, reconnected and recombined over and over again. Only a very resilient tube system can meet these requirements, as Professor Abels explains: “We can build the system with the students – usually a group of around ten – in the space of half a day. It all has to move very quickly, because we want to teach the expertise behind the method. And we have to be able to dismantle everything again and again.”

The aluminium tubes in Profile Tube System D30 have proven themselves in practical applications because the Lean Production Building Kit System was developed for day-to-day use in industrial environments. “The system remains intact and suffers barely any damage,” states Professor Abels, “thanks to the fastening technology, we can use it over and over. And that is very important, particularly in a university environment.”

New ideas for lean work benches

The advantages of a building kit system for lean production become clear when practising how to extend and reconfigure structures. One typical example is switching from centralised storage to a conveyor rack storage system, which involves students having to relocate an entire unit of lean work benches into a different room.

That can only work if the building kit system can ensure fastenings are stable over the long term. “We don’t always arrive at the same solution,” points out Professor Abels, “a storage rack designed by one group might look completely different to one designed by another group. We have this flexibility in the system, which means we can reproduce what our students want to do. If we also want to incorporate future innovations, we are very well placed to do just that.”

That was the last part of our interview with Professor Abels. However, we will continue to look at the principles and development of the lean philosophy in future. Simply subscribe to the blog – and you can rest assured you won’t miss any updates.

After introducing a few types of waste and countermeasures in the first part of our Muda series, we are taking up the thread again. This time, the following three Muda take centre stage – processing, overproduction and rectifications and errors. First, though, it is important to mention the continuous improvement process (CIP), which is a decisive tool when seeking to avoid Muda.

Planning in line with the continuous improvement process

Waste in production can often be traced back to superfluous processes or excessively complex sequences. When applying lean production methods, companies should therefore preferably plan for the minimum and improve the preexisting infrastructure step by step. In the lean philosophy, this process of striving for continued improvement is known as Kaizen. When applying the continuous improvement process (CIP), the basic framework can always be readjusted further down the line. As a result, lean production enables companies to use plants over a long period of time and gradually modernise them with add-ons and extensions.

Muda No. 5: The role of processing

Heavy lifting, difficult-to-reach materials, unnecessary worksteps – these are just some of the many different ways that time, effort and money are wasted in the production process. This type of wastage can usually be traced back to superfluous processes or excessively complex sequences. However, the tools always have to be right for the specific task at hand.

That is why lean production emphasises the gradual improvement of the existing basic infrastructure. This prevents over-engineering and retains flexibility. If the design allows, a basic frame can always be modified later on so that it can be extended. It is not uncommon in lean production for plants to be used over a long period of time, being gradually modernised with add-ons and extensions.

The most frustrating Muda: Waste due to overproduction

Manufacturing products before they are needed ties up capital and drives up warehousing costs. What’s more, the quality of products can also degrade substantially while they are being held in storage. Rejects are by far the biggest source of waste among the seven Muda and have the most obvious disadvantages.

Consequently, production has to be flexible enough that it can adapt to the actual take-up of products or materials (pull principle). Being able to restrict, increase or convert production systems is one of the most important aims of lean production and this is usually easier to achieve with small, flexible units than with monolithic systems, which are only efficient when producing high unit numbers all the time.

The right way to handle errors – accept them and rectify them

In classic production systems, rectifications and errors are frowned upon. By contrast, lean production boasts a fault culture that strives for perfection by learning from mistakes. Every error that is discovered is valuable because it represents an opportunity for long-term improvement. Declaring a production problem taboo and trying to ignore it also leads to waste. The seventh Muda is the waste of a missed opportunity to learn something.

Companies that pursue the continuous improvement process must be willing to learn. CIP is therefore one of the fundamental principles at the heart of quality management to ISO 9001. As a methodology, it demands that companies keep a close eye on all work stages, ensuring they are continuously monitored and that findings are fed back. It also places particularly high requirements on production systems – the more specialised and complex they are, the more difficult it usually is to adapt them.

This is the concluding part of our series on the seven Mudas. However, we will continue to address the numerous concepts associated with lean production.

The world of mechanical engineering is as fascinating as it is complex, and students of the subject find themselves facing countless technical terms, models and concepts. Thankfully, that is precisely where the item Glossary can help. 

Claims and objectives  

Of course, to use a technical term correctly, you need more than just a direct translation. That is why we have also incorporated close to 20,000 example sentences into the system as an extra service. Since these sentences are based on all the item documents that have been translated, they are not vague theoretical reflections, but rather direct examples from day-to-day scenarios in mechanical engineering. That way, users can always benefit from the surrounding context in which the terms are being used.

The item Glossary is designed to be widely available to anyone, anywhere, free of charge – and that is why it has been developed for the web and as a smartphone app (Android and iOS). Whether looking something up quickly when meeting with your study group or preparing on your way into uni on the train, this flexibility fits perfectly into everyday student life. As this is the first resource of its type on the market, we are happy to lead the way.

Starting gun for the item Glossary

It was not just the subject matter that made it imperative to adopt a systematic approach. We started by selecting a list of keywords and technical terms from the topic areas that all mechanical engineering students are expected to master as they begin their studies – mechanics, engineering, manufacturing processes, material strength, materials science. We then looked at which specific topics required more detailed explanations. So far, 860 detailed explanations have been added to the glossary, with a further 140 prepared and awaiting translation.

When the idea for the item Glossary was first developed, it quickly became clear that we would have to involve external authors – particularly in view of the ambitious aim and scope of the project and the necessary illustrations. The next step was to find a faculty that could act as an authority and provide quality assurance every step of the way. We were extremely happy when Prof. Dr.-Ing. habil. Dr. h. c. Heinrich Kern from Technische Universität Ilmenau agreed to help. As the head of the Department for Metallic and Composite Materials, he was only too pleased to provide specialist support.  

Great feedback from students and the outlook for the future

At the end of 2014, just under half a year after the item Glossary was launched, we conducted an acceptance study at 68 universities in Germany and Austria. The results were unanimously positive. The issues evaluated in the study included ease of use and display features. Here are some direct quotes from students who took part in the study: “It’s all self-explanatory. Super!”, “It’s a super dictionary – finally I don’t have to spend ages searching for a translation” and “Very clear. The function that suggests search terms is very helpful. You can see everything in one place.”

But there is still work to be done on the item Glossary. There are plans to integrate more detailed links to further improve user-friendliness. Once the thousand mark has been reached for the detailed glossary entries and links have been optimised, we’ll be taking another close look at the glossary to work out whether we can add to the entries and how best to go about doing that.
We will soon be publishing more articles about our activities in the higher education sector. All you need to do to make sure you don’t miss out on any updates is subscribe to the item blog.

The basic function of a work bench system is fairly straightforward – it should ensure that the work carried out at it is as efficient as possible.

Traditionally, benches have been assessed purely in terms of mechanical criteria. They should be stable, able to withstand loads and offer some flexibility so they can be adapted for different types of work. Workers should also be able to complete their work safely and quickly.

Although most of the work bench systems that are available today satisfy these requirements, many suppliers have given less consideration to other ways that efficiency can be improved. This is where the real challenge lies – sound, functional design.

Ergonomics for health

The key question is this – why are work benches in industrial companies so rarely designed to be ergonomic? Constrained postures, obstructed views and bad lighting often make work more difficult and reduce efficiency, particularly where all these factors combine.

Poor working practices cause stress and strain – and ultimately make workers sick. By contrast, ergonomics protects the health of employees, significantly reduces illness rates and boosts efficiency. For many years, the Campaign for Healthier Backs (AGR e.V.) has been championing the cause of ergonomics in the workplace and celebrating products that meet the highest standards in this area.

Ergonomics for motivation

All this has a direct impact on working sequences and processes. If personnel understand a workflow intuitively, it will quickly become an effective routine. Custom modifications can also be made in next to no time and, if production requirements change, setup time is kept to a minimum. Indeed, personnel can usually make the necessary adjustments themselves. This also boosts their personal engagement with their work, which has benefits on a psychological level.

Content precedes design

“Design without content is decoration” that’s how web designer Jeffrey Zeldman put it in 2008. A work bench system that is wonderful, but doesn’t work, has no chance on the market. However, the latest findings in psychology and medicine show that it’s time we spoke more about these aspects of design.

In the 1960s, a metalworking production hall would be dark and dirty. But what does it say about a company, when it leaves its workforce to toil in sad, dingy environments? Again, it was only when studies revealed a clear influence on efficiency that company bosses took notice and invested. Today, state-of-the-art production facilities are bright and clean with a friendly design language.

Appreciation through design

The appreciation that companies show their workforce in the form of high-quality, functional and ergonomic work benches has a significant influence on output. When working in a pleasant environment, personnel exhibit high levels of motivation and commitment. Employees also feel good and are ill less often.

Moreover, ergonomic work benches with a standardised design are integral to a company’s corporate design, as they have a major impact on corporate culture. Internally, they ensure that personnel identify more closely with the company and enjoy job satisfaction – externally, they project an impressive image to customers and suppliers.

Industrial design brought to life

A subtle design language of straight lines communicates order and organisation, where everything has its place. Work benches don’t just look very tidy and well structured, they also stay that way. Thanks to wide-ranging adjustability and a whole host of additional options, personnel have a great deal of freedom to customise their workstation to their physical and occupational needs. Sustainable, ergonomic work bench design takes a great deal of psychological and physical strain off employees.

Impressive feedback

This positive impression has been reflected in the opinions of judging panels for a whole range of prestigious design awards. For example, the Work Bench System has been nominated for the German Design Award 2015. Parts of the system have already won the Red Dot Design Award 2014, the iF product design award gold 2011 and the iF Industrie Forum Design Hannover award 1997.

It was 21 June and the big day had arrived. In Düsseldorf, soapboxes careered over the course for the second time, and of course our newly founded “item racing team” wasn’t going to miss out.

One spontaneous idea; enthusiastic team mates

“At first, it was just a passing notion I had while surfing the Internet. I happened to come across an article on last year’s Düsseldorf soapbox race,” recalls Mostert, thinking back to how the project started. The vague idea soon transformed into an impassioned project. It didn’t take long to find willing volunteers for the team from the Development and Industrial Design departments – Nicolas Kellmann, Ralf Schmidt and Oskar Zaworski. Together, they set about designing their soapbox – using our own D30 profiles.

Most people are familiar with the term, but what exactly is a “soapbox”? It is defined as a small, self-made, four-wheeled vehicle with no drive system, which means soapboxes can only be raced on a downhill course, or need a ramp to “get them going”. The race in Düsseldorf started from one of these ramps, which set the racers hurtling from Mannesmannufer towards the Rheinkniebrücke bridge. Although the “item racing team” was entered into the companies cup, an amateur race event, it based its design on the demanding technical specifications for professional racers.

Free-time fun and a serious undertaking

Of course, for many amateurs, a soapbox race is just a bit of fun. Indeed, the vehicles that took to the starting line in Düsseldorf included a europallet and an (astonishingly fast!) zinc tub. But for our team of passionate tech-heads, honour was at stake! Intensive preparations kicked off four weeks ahead of the race, with the full support of colleagues and the company. For example, the team were allowed to use the company’s machinery and a company van emblazoned with the team logo was provided to transport the “lean” (but not so mean) soapbox. 

Two races were held on the big day, as part of a colourful family-friendly celebration on the banks of the Rhine. Nicolas Kellmann was the first team member to complete the course, and picked up the second-best time. And, although the team missed out on a podium place by just one second after Ralf Schmidt’s race, the team members are now hungrier for success than ever. Mostert, the man who started it all, offers his perspective: “It was a type of experiment so, from that point of view, we’re very happy. But that is by no means all of it. The ultimate aim is to get on the winner’s podium. We’re going to keep on improving on every detail!” That is certainly an outlook that reflects the spirit of lean production.

Boosting profitability with lean production

Lean production focuses on identifying and tackling the sources of waste in production. As the original concept was developed in Japan, the term “Muda” is often used. This Japanese term means an activity that is pointless and a lack of purpose or sense.

In this and the next two blog entries, we want to take a closer look at the seven classic types of waste. These are:

1. The movement of materials
2. Stock levels
3. Movement
4. Waiting times
5. Processing
6. Overproduction
7. Rectifications and errors

Recent research on lean production has resulted in two additions to the seven classic Muda identified by Toyota in the 1950s and 1960s – a lack of ergonomics and untapped employee talent.

Value-stream mapping – how to tackle waste in the movement of materials

Important resources are used every time a workpiece is moved from one place to another. However, instead of generating added value, time spent on transport simply increases costs by extending capital lockup and demanding more outlay in terms of energy and personnel. What’s more, each time something is moved, it is put at greater risk of being damaged or suffering quality impairments.

A lot of waste can be prevented by carefully planning the individual steps in a workflow, and that includes arranging the various locations where work is carried out so that they are closer together. At the same time, the individual processes themselves need to be coordinated with each other. The aim of value-stream mapping (VSM) is to optimise throughput times and to time the individual stages in a workflow as accurately as possible. This includes taking into account set-up times when different products are being made on the same machinery or at the same work benches.

Optimising the flow of materials with CIP

The continuous improvement process (CIP) is ideally suited to optimising material flows. Employees can offer valuable information on where waiting times are incurred and which transport routes are too long.
Companies can reduce the movement of materials and manage this movement in a more efficient way by using intelligent interlinking systems between workstations and customised transport solutions. Second-generation lean production building kit systems therefore offer a single system for intralogistics and factory equipment that ensures a smooth transition between work and movement. Using aluminium tubes with stable aluminium fasteners results in strong holding forces that are not impacted by dynamic loads and therefore have a positive impact on durability. Furthermore, stable constructions can be built with less material.

Using Kanban to reduce warehouse stocks

High stock levels are always a warning sign. The aim is to optimise production processes so that stocks of preliminary and intermediate products do not get too big. The Kanban principle is often used as a means of managing sequences. Kanban is a Japanese word meaning “signboard” or “billboard” and describes a simple method for ordering materials based on actual consumption. Included with every delivery, these order cards clarify the current flow of goods in line with the pull principle.

One of the typical applications of lean production building kit systems is the construction of Kanban carriages or trolleys that enable operators to quickly resupply workstations. Second-generation building kit systems also apply the rules of lean production to themselves. Experience has shown that the “one fastener for all” principle helps to keep warehousing requirements low. Instead of having to stock a whole range of specialist fasteners for various scenarios (connecting together 2, 3 or 4 tubes), companies can complete all their engineering tasks using just one standard product for 90° connections.

When it comes to boosting the efficiency of industrial work benches, ergonomics is often overlooked, says work bench expert Marius Geibel from item in this interview. However, companies can achieve three benefits at the same time: Eliminating uncomfortable movements boosts efficiency and motivation – and lowers illness rates. 

The term ergonomics covers a lot. Why should companies engage with it?

Can specific figures be put on the benefits of ergonomics? Is there any hard evidence?

How difficult is it to design work benches to be ergonomic?

How can you actually tell whether a work bench system is ergonomic?

Combined sit/stand workstations have long been a feature of the “office world”. Can this same method be applied to industrial production? 

During a hot summer, there is little that can compare with the refreshment provided by a delicious juice. Now, “Juice on Wheels” has developed an original and environmentally friendly concept for producing, transporting and selling this tasty cooler.

At the heart of the concept is the notion that a healthy product should be produced and taken to customers in a similarly conscientious manner. So, instead of eating up power, polluting the environment and wasting resources, the concept relies on a solar-powered, all-in-one solution. In fact, the mobile OJ bar doesn’t just take tasty drinks to people, it also makes them. And our Profile Tube System D30 is on-board, too, as an essential component in the bar, which is the brain-child of a Dutch team headed by Peter Blesgraaf. 

Creative and environmentally friendly 

The bar is attached to the rear of a professional cargo trike that can carry a cooling system, juice press and storage space. However, the real secret to the bar’s success is its design, which is both stable and light in weight. While searching for suitable materials, Peter found what he needed during a visit to the LogiMAT trade fair in Munich. It was the low weight of our profile system that won him over, and he built everything himself. It also turned out to be quite handy that our Delft branch is just 10 kilometres from his house. 

But it isn’t just the mode of transport that is green, the nutritious juice is also produced in an environmentally sound process. When thinking about how best to make the juice, Peter and his team came up with a bright idea: A press powered by batteries that are charged by a solar panel, which doubles-up as a roof. The batteries also ensure that the ice used to cool the juice doesn’t melt away too quickly. 

Across Europe with ease   

Because the trike can carry 300 kg, the bar can be stocked with countless oranges, bottles for filling and even used bottles for recycling. What’s more, “Juice on Wheels” is an extremely flexible vehicle in two important ways. Firstly, thanks to the use of D30, the team has been able to make minor improvements after every time the bar has been out. And, secondly, as a three-wheeled vehicle, the bar can also go anywhere pedestrians and cyclists can. That means getting into indoor spaces and trade fair tents is no problem either. 

The project is still currently in the testing phase, but the first collaborations with educational institutes and charitable organisations, for example, are already starting to bear fruit.  The team still take to the road with two vehicles though – the juice bar and a small supply trike carrying more oranges. A European tour is very much on the cards and will take place as part of a renewable energy campaign. The next destination on the list to enjoy cool refreshments this year is the Côte d'Azur. 

We’d like to wish the “Juice on Wheels” team all the best, happy in the knowledge that they are using our profiles to take healthy refreshments across Europe. Would you like to find out about other ways that the profiles are used? If so, you should enjoy our regular blog reports. Subscribe to the blog and you can rest assured you won’t miss a thing.

More about Juice on Wheels on Facebook.

As the lean philosophy gains ground in industry, demand for appropriate training courses is growing, too.

Lean production focuses on minimising the wastage of time and materials. It also aims to resolve as many faults as possible at their source, so that the risk of production accidents can be lowered and customer satisfaction raised. This is achieved by maintaining a consistently high quality standard while also working as closely as possible to the customer’s specified cycle time. Throughout all this, it is essential to keep an overview of the entire company. Lean production starts in management and filters out through production to every corner of the business.

Lean Management as a competitive advantage

The lean movement has its roots in the Japanese automotive industry. Indeed, its Oriental ancestry is still very much evident in the names given to numerous lean production methods – Muda, Kanban and Kaizen are just three examples. However, the principles are suitable for all branches of industry and companies of all shapes and sizes. In fact, small and medium-sized businesses can benefit from overhauling old working processes in a very short space of time.

All the same, managers need to learn the various methodologies before they can put them into practice. Ansbach University of Applied Sciences has earned itself an excellent reputation as a centre of learning for lean production and has established a dedicated institute – the CETPM. The Lean Production Master is just one of the qualifications available through a whole range of workshops at the institute, which specialises in training industry experts. 

Learning lean production efficiently

To meet the needs of its students, the institute has to transfer a comprehensive package of knowledge within a very tight timeframe. It is important that teaching content can be put into practice straight away. For example, as part of this strategy, course participants completely reconfigure actual production environments several times over in the space of just two days. Steel constructions are too inflexible for this fast-paced approach, while simplified structures engineered in cardboard are far too unrealistic for practical purposes.

More about the CETPM:
en.cetpm.de

Quality management can be a big problem when manufacturing electronic components. All the various parts have to work perfectly over the long term, particularly in critical areas such as power supply. If employees are to make sure products do exactly what they’re supposed to, they need the ideal working environment.

Of course, one aspect of creating an optimum working environment is to ensure production personnel are working with error-free components. That might sound obvious, but it’s a critical factor when handling electronic components, which can be damaged by an electrostatic discharge (ESD) before they even reach the assembly stage.

The invisible danger

An ESD is problematic for two reasons: Firstly, if a production environment has not been specially adapted, there is a whole range of conductive materials that could trigger an ESD. These materials could be on the work bench itself, or the transport trolley used to fetch individual parts from storage. If employees are not using special equipment, they themselves can trigger an ESD when they come into contact with a part. The second reason is that an ESD is practically invisible. Discharges of even just 100 V can be disastrous – and that is well below the level that humans can sense. What’s more, the damage itself is invisible to the naked eye and will therefore go unnoticed, unless it causes the immediate and total failure of the component.

Solutions for ESD protection

As a premium electronics manufacturer and specialist in energy management, Bachmann GmbH & Co. KG had to find the best way to adapt its production process sequence to protect against ESDs. Every workstation also had to be designed so that personnel could complete their production steps in an ergonomic posture and without wasting time and energy on unnecessary reaching movements. You can find out in a detailed user report how Bachmann and item implemented a comprehensive concept for an entire production hall and how personnel benefited directly from that concept.

The second part of our history of lean production looks at the new role of employees and the continuous improvement process (CIP).

The limits to industrial production

During the first and second phases of the industrial revolution, the success of a factory rested on the following approach: Dividing up work steps, optimising their execution and repeating them as fast and as frequently as necessary to boost production and drive down unit costs. That works well when the factory is producing the same product in the same way all the time.

However, after the Second World War, businesses in Japan chose to pursue a different strategy. Instead of relying on straightforward mass production, they focused on rapid product innovation. The fast pace of change required a new production strategy. Employees were included in planning to ensure that both the product and production methods would change in tandem. The concept of the continuous improvement process (CIP) was born.

Toyota – the company at the heart of Kaizen

Taiichi Ohno and Shigeo Shingo developed this new approach at Toyota in the 1950s. They moved process planning from the top of the hierarchy to the place where the work was actually being done. To reduce capital lockup, they integrated suppliers closely into in-house production planning, which operated on the pull principle – in other words the flow of materials was not determined by the speed of the production line but by sales volumes. Production adapted to demand and was optimised so that it could respond to changes flexibly. Ohno and Shingo also rolled out a continuous improvement system to ensure production methods could be refined on an ongoing basis instead of in stages.

The “Toyota Production System” (TPS) gave rise to lean production and Kaizen, which enable companies to respond faster to changes and therefore be more agile on the market.

Since the 1980s, the Toyota Production System has also been modified outside Japan. It took around 30 years for the benefits of lean production to become so compelling that companies across the entire world started to study and adopt the approach. Another 30 years later, principles such as continuous improvement and consistent quality management have become standard for cutting-edge production.

Kaizen and the continuous improvement process

The term Kaizen refers to the central element or fundamental attitude towards planning. Kaizen is made up of the Japanese words for “change” (Kai) and “for good” (Zen). Kaizen is a production philosophy that sees improvement as a never-ending process because it is not possible to be satisfied with the status quo. No area is unimportant or impossible to improve – you just need to look closely enough. The concept of Kaizen developed at Toyota was adopted as a standard production practice under the title of “continuous improvement process”.

Building kit systems support CIP

CIP is a component of quality management to ISO 9001. In order to make continuous improvements in small steps, companies have to combine expertise with responsibility. Employees must have the tools and authorisation they need so that they can implement small improvements independently. If every small change has to be approved, the workflow goes against the principle of personal responsibility and would drive up planning costs.

Lean production building kits are system solutions that make it easy for users to build shelving units, racks, transport trolleys and other factory equipment. Ideally, a CIP workshop will be incorporated into a company’s production system so that teams of workers can use it as and when they see fit.

Girls’ Day came to item on 23 April 2015. The aim of the Germany-wide initiative is to inspire young girls to consider careers in fields that are traditionally male-dominated, specifically science, technology, engineering and maths (STEM).

Once again, it didn’t take long to find 12 girls aged 10 to 16 who wanted to spend this special day at item in Solingen. Although the experience was primarily about gaining an insight into the work of a technical product designer, IT specialist for system integration or IT specialist for application development, having fun with engineering also had a very big part to play.

Apprentices showcase their career of choice

The potential future engineers started their day in the workshop, where they were tasked with joining together two sections of profile at a right angle. Although some of the girls were far from familiar with a production work bench, each of them stepped up to the challenge and drilled her own installation holes.

The task was followed by more relaxed, practical workshops, which were led by apprentices. After a brief presentation of IT training options, one group got hands-on and dismantled a complete PC. An apprentice from IT explained how each of the individual components works and answered the participants’ numerous questions. A female apprentice technical product designer gave a presentation on her chosen career and demonstrated how she uses a CAD program, taking a ballpoint pen as an example.

Combining theory and practice

A key aspect of the initiative in Germany is giving girls hands-on experience, and so the participants put what they had learned in the morning into practice after lunch, when they used our profiles to build a picture frame. And when elements didn’t quite want to fit together straight away, a few taps with the item mallet was all that was needed. The frame was completed with a personal snapshot from the morning, which of course all the participants got to keep.  

And that brought an end to a “cool day” that many of the girls felt turned out “much better than expected” and was over all too quickly at 3 p.m. Even if a lot of Girls’ Day participants don’t go on to pursue a career in science and technology, the campaign still helps to tackle the misgivings that many girls still have about STEM fields as a result of ingrained gender stereotyping.

An opportunity for both parties

“Some girls also have some pretty big misconceptions about the work of a technical product designer. Even the term ‘design’ is a bit misleading in the career title,” explains Jörg Schiemann, who is responsible for training apprentice technical product designers, adding: “Later on in your career, you’ll seldom end up designing a beautiful car. What is really in demand are more functional and efficient solutions for very specific projects.”

However, that is what makes the job of a product designer so interesting. To have a successful career, you need specialist qualifications, of course, but creativity and a unique approach to problems are just as important. That is what makes a technical product designer such a valuable – and interesting – member of the team.

Although every new application area brings with it specific requirements, the ultimate aim is always the same – producing as many fault-free products as possible at the lowest possible cost.

The costs of conventional cleanroom technology

The last point in particular is traditionally a decisive factor in cleanroom technology. Conventional cleanrooms like those used in the semiconductor industry are usually static. As a result, in the medium term, they are responsible for a large share of the initial investment in the form of additional operating costs. The financial risk is similarly high when in-house cleanroom requirements are not planned perfectly.

Renting cleanrooms on a flexible and low-cost basis

A rental cleanroom is a good alternative, particularly when a company is manufacturing under cleanroom conditions for the first time due to the requirements of a new customer. The MRR-01 model from Colandis can be set up in just a few minutes on an area measuring 20 m². Nonetheless, it boasts all the key features of a cleanroom – from lighting and fan-filter technology to an electrostatically dissipative floor. The mobile cleanroom satisfies airborne particulate cleanliness class 5 to ISO 14644, is supplied in two castor-mounted containers and can be assembled without the need for any tools.

The MRR-01 has been developed to meet the requirements of small and medium-sized companies, where it can be used as a test environment for planning cleanroom requirements in virtually all environments. 

Welcome to the new blog from item! Just like our product range, item’s online presence is also constantly evolving. Whether on Facebook, YouTube or at item24, there is now a rich and varied collection of articles, videos, and other content detailing our activities around the world.

We designed this blog to pull together the very best stories with and about item. We want to share the know-how we have acquired over the past 40 years with you. What’s more, we’ll be telling you about projects large and small that are particularly important to us.

Our user reports also offer a fascinating take on the countless possibilities with item. They provide first-hand accounts of success stories, showing how the item building kit systems have so far found their way into a huge range of industries and application areas.

We are delighted to kick off this project and hope you will become one of our regular readers. You can also subscribe to our blog to have new entries sent  direct to your e-mail inbox, or use the RSS feed. 

Axel R. Dorfer, Head of Channel Marketing item industrietechnik GmbH

Lean production has been causing a stir since the 1970s, when it introduced the principle of continuous improvement and narrowed the focus on maximum quality. More than 40 years on, is it still relevant?

In this interview, engineer Stefan Armbruster reveals the potential that has yet to be tapped and highlights the factors that are often undervalued in companies.

Stefan Armbruster is a market expert in lean production, a team leader in the Development department at item and the Product Manager responsible for the Lean Production Building Kit System.

Lean production is a concept that has been around for a long time. Why should a company put it into practice in the 21st century?

Because the principles have been proven to work. If a company can boost its efficiency by reducing waste, it will lower its costs and improve its processes. When it is put into practice, continuous improvement delivers a lot more than simply hoping or waiting for giant leaps in progress.

How much more lean can a production system get? Hasn’t all the potential been exhausted already?

Lean production isn’t a state that companies try to attain, it’s an attitude that guides businesses in the right direction through a series of steps. We’ve only just started tapping into the potential of lean production. After all, there are still big companies that have done virtually nothing to explore this approach. There is still a great deal that can be achieved in these cases.

“Lean production isn’t a state that companies try to attain, it’s an attitude.”

The more progress a company makes with lean production, the smaller the steps actually have to get. However, even Toyota – the company that first developed the lean concept – would never claim that it has eliminated all waste. If you decide you’re totally satisfied with what you’ve achieved, you stop getting better. After all, no product development team would ever say: “That’s it, we couldn’t build a better car.”

Where in a company is the most waste generated?

We talk about the seven Mudas, or classic types of waste. Overproduction is seen as the worst as it incorporates most of the others. Recent research has also identified two more Mudas – squandering talent and inadequate ergonomics.

How is inadequate ergonomics a type of waste?

People are very different in terms of their size, strength, age and so on. If operators have to adapt to their work benches, they cannot perform to their full potential. However, ergonomic work benches adapt to their operators, which boosts productivity and lowers illness rates. A company can really benefit from actually utilising the full potential of its employees instead of wasting it. Employees also benefit because they are healthier and much more motivated. It’s a real win-win solution.

Don’t methods like that go against the lean principle if you need additional tools and aids?

Quite the opposite. Lean doesn’t mean stripping everything away, it means avoiding what is unnecessary. However, you need more of the things that make working practices more productive. Nobody would simply get rid of a metal press to save on electricity. Lean production building kit systems help personnel build precisely the equipment that will make them more productive, and build it on-site.

“Lean doesn’t mean stripping everything away, it means avoiding what is unnecessary.”

What aspect of lean production is most undervalued?

People. The skills and motivation of the workforce is the basis for any and every improvement. If a company doesn’t support its personnel so that they are motivated enough to look for improvements, then it has already failed to introduce the lean philosophy. You can’t compensate with pull, Kanban, Karakuri and other such systems. The way that errors are dealt with is often a good indicator of whether or not a company has been able to incorporate the lean philosophy into its HR culture. At Toyota, they really value errors because companies need them if they are going to learn and therefore be able to improve processes and products. They don’t hunt down the guilty parties, they look for better solutions instead.

Where are the most problems encountered when putting lean production into practice?

When it comes to work scheduling, personnel need a degree of freedom so that they can implement the improvements that are necessary. Very few employees will use their free time to build factory equipment for their employer. What’s more, personnel need to have appropriate training so that they can recognise the potential that lean production building kit systems offer them in their job. If those things are missing, employees lack motivation and expertise and a great many opportunities for improvement will be missed.

In terms of factory equipment, the requirements are clear: It needs to be as self-explanatory as possible, personnel should be able to adapt it quickly and easily and it has to be reliable. Equipment that doesn’t offer long-term stability is no real help at all.

“When it comes to work scheduling, personnel need a degree of freedom so that they can implement the improvements that are necessary.”

Isn’t it the job of employees to build factory equipment that lasts?

The problem is not with the employees. You should be able to expect a toolkit like a lean production building kit system to produce stable component fixings that can cope with strain over long-term use. If the fixings on a transport trolley need to be constantly retightened because of creep, that’s also a type of waste. Fixings and fasteners are only really lean when they hold firm under strain – without having to be retightened.

item offers its own Lean Production Building Kit System. Which components do you think are particularly important?

First and foremost, the roller conveyors. Before anything else, you need to look closely at the containers and their qualities. Many people don’t understand just how important it is to pick the right roller element for the goods that are being conveyed. That is particularly important when you want to put in place Karakuri applications for low-cost automation. Another key component is the preassembled Fastener. You simply take it out of its packaging and a few seconds later it’s fitted in place. The component that our customers use the most no longer has to be assembled from several individual parts. It might sound unimportant, but in practical terms it saves an unbelievable amount of time and stress! Only item offers a product like this, and it’s a good example of Kaizen in practice. The preassembled Fastener delivers a better result in less time. That’s exactly what lean production is all about.

What kind of requirements will building kit systems need to meet in the future and how does linear technology fit in?

In this interview with German engineering portal “Konstruktionspraxis”, Oliver Teckenberg, product manager for mechanical engineering and automation at item, answers this question and more.

Mr. Teckenberg, what are the current trends in mechanical and plant engineering?

Customers are finding it increasingly important to have not just a comprehensive building kit system, but also access to ready-made solutions for their fields of activity. Solutions like these significantly reduce their design and engineering outlay and mean they can plan ahead with a great deal more certainty. A comprehensive building kit system also allows users to combine solutions as necessary and extend them to create a functional plant. Extensive sensor and actuator systems can also be integrated into the plant in line with the Industry 4.0 concept.

Building kit systems and the principle on which they are based are on trend. How does that affect your research and development work?

We offer our customers one of the most extensive building kit systems available for mechanical engineering. Besides continuing to develop this building kit system, we are also working in parallel on coordinated solutions that are based on existing components and designed for a range of product areas. For example, we exhibited 25 new solutions for ready-to-install Linear Units at last year’s Motek. It was important that these should be fully compatible with the MB Building Kit System and other solutions such as enclosures and guard systems for production and machine enclosures.

Form and flexibility are crucial considerations when working on a new development, but do materials have a role to play, too?

Yes. After all, industrial production is becoming much more automated and short cycle times are hugely important if processes are to be cost-effective. This means that lightweight materials should be used that enable highly dynamic movements while keeping energy usage to a minimum and thus supporting a high standard of overall energy efficiency. Item uses a lot of aluminium, which is low in density but high in strength. What’s more, the materials we use are RoHS-compliant and in line with the Europe-wide REACH Directive.

Do you think linear slides will start to appear in new applications in the near future?

The linear units of the future will deliver high output in the tightest of spaces. That is a general goal. However, they won’t be confined to industrial applications in the future. I believe we’ll start to come across more and more of them in our day-to-day lives. One current example would be the pharmacies that use linear units in plain view of customers as an automated means of supplying medicines in a very compact space. Those huge pharmacy cabinets are a thing of the past now. Applications like these, where the linear units can be seen by end customers, bring new requirements. The linear units need to be quiet and satisfy high design specifications.

Does item already offer linear slides that are suitable for applications such as these, for example, quiet-running models?

item Linear Units are based on a range of drive concepts combined with roller guides. Roller guides offer a long service life and are very smooth running. Encapsulated Linear Units with specially developed timing belts, such as our Linear Unit KLE, help to keep noise to a minimum. Design is also a big priority at item. In fact, Linear Unit KLE won the reddot design award in 2008 for its outstanding design.

Many thanks for talking to us. 

Technological devices of all shapes and sizes are now crucial to our day-to-day work and private lives. However, the huge variety of products that are out there – from smart watches to jumbo jets – does pose a potential problem. And that is not all, as the components in these products get ever smaller, it also gets more difficult to make sure they can all work together smoothly.

More disruption and more vulnerability

Any electric or electronic product that doesn’t have the appropriate shielding is vulnerable to electromagnetic disruption from the outside world. At the same time, every device emits its own such disruption. What’s more, the very small structures in state-of-the-art products are significantly more vulnerable to disruptive impulses. Part of the solution is to have a precisely defined set of guidelines that will ensure all products are protected by adequate electromagnetic compatibility (EMC).

The relevant framework in the EU is the European EMC Directive. It regulates “the ability of equipment to function satisfactorily in its electromagnetic environment without introducing intolerable electromagnetic disturbances to other equipment in that environment.”

EMC Test NRW

It is down to the manufacturer or importer to ensure a product has adequate EMC, and they are also responsible for its CE labelling and/or EC Declaration of Conformity. If companies are unable to conduct the necessary series of tests themselves, they can outsource the work to specialist test institutes. One such institute is EMC Test NRW in Dortmund, Germany. During EMC testing, measurements are taken to assess both the electromagnetic disruption emitted by the product being tested and its own resistance to such disruption. As well as testing assemblies from industrial companies, the facilities at EMC Test NRW are also large enough to accommodate buses and construction and agricultural machinery.

Besides testing the electromagnetic compatibility of products, the methods used by EMC Test NRW can also be applied to individual materials. This is important when materials need to offer electrical insulation and high transparency with regard to electromagnetic waves – for example if being used in the base frame for a measuring table. That is why the metal-free Profile KH from item also had to be tested and it has be for applications up to 2 GHz.

How a virtual supermarket is helping patients with brain function disorders rehabilitate into daily life.

Are long shopping trips really good for us? Men and women might often disagree about that, but the shopping experience is very much at the heart of a treatment Bielefeld University has developed for people with brain injuries. Depending on what type of accident or disease a patient has suffered, very different areas of the brain can be affected. Sufferers could experience gaps in their memory, problems with their visual perception or difficulties with their general sense of orientation.

Finding the most efficient training

This is precisely where the OctaVis training environment comes in, a project run by the CITEC cluster for excellence at Bielefeld University. Although patients can experience practically any everyday situation as a 3D virtual reality simulation, it quickly became clear that a normal supermarket is the ideal scenario for rehabilitation purposes. The patients carry out their training inside a ring-shaped cabin with multiple monitors that create an all-round view like an almost genuine shopping trip.

Rehabilitation inside the virtual supermarket

The tasks the patients undertake are extremely relevant to the limitations that can result from a brain injury. They have to keep track of shopping lists, find products in the market and tap the products on a screen to place them in a basket. After a few training units, patients usually learn to complete their shopping tasks faster and more accurately, but their performance also improves in other spatial/visual exercises, too. Stimulated by this realistic training, other parts of the brain start to take over more and more of the tasks previously handled by the damaged part.

One of the most important automotive trade fairs in Mexico took place this week – Automotive Meetings in Queretaro. Naturally, item America LLC had to be there.

Attended by around 500 representatives from the international automotive industry, the event is the best B2B forum for experts to share their know-how. Our colleagues from item America LLC were there, too, and had a number of very interesting meetings.

It wasn’t just the German football squad that had cause to celebrate in Brazil last summer when it won the World Cup – Germany also took first place in a discipline of the RoboCup. 

The competition staged most recently from 19 to 25 July 2014 in João Pessoa, Brazil, is well known for its football tournament that pits robots and artificial intelligence of various classes against each other. However, the fun-packed programme of the RoboCup is just one element of the annual conference that discusses the latest developments in AI and robotics.

Robots as aide and saviour

And while it will still be decades before robotic strikers can match their human counterparts, Team Hector from Technische Universität Darmstadt put Germany at the top of the winner’s podium in the no-less enthralling Rescue discipline. In this additional competition, search and rescue robots are tasked with tracking down victims in simulated disaster scenarios.

In the future, rescue robots will be deployed in situations where conditions are too adverse or even dangerous for human helpers. As a result, they need to be able to operate independently in the target zone.

All Images © 2014, Team Hector Darmstadt. More about Team Hector on Facebook.

The route that Anne took led her into distribution channel marketing. When working on her degree dissertation while completing a combined work and study course in business, Anne developed a concept for what was at the time a brand new product group – “Work Bench Systems”. However, instead of following this up by starting a course on the “Culture and Society of Asia”, Anne brought her skills straight to item as a trainee in 2010.

Today, her many projects include product group marketing in Europe, university marketing, identifying promising future sectors for new and existing products and marketing for Asia: “I like item because I can work independently and play an active role in shaping my career.”

Always in step with the times

Babette has also been active in developing her career. She joined the company just under 20 years ago as a technical drawer in the development department, and just two years later helped to set up a completely new department. The new team was tasked with designing and producing the item product catalogues. Since then, the rapid pace of technological advances has been a constant theme in her work – from the growth of digitisation in printing to the rise of the Internet.

Babette has also benefited from the march of technological progress on a personal level, too. Thanks to a virtual workstation, she was able to play an active role at item throughout her maternity leave. What’s more, the flexitime system in place at item made it much easier for her to come back to work. Babette’s main responsibilities in product marketing currently relate to online campaigns and the entire print sector in a whole range of languages: “I like item because our personal circumstances are taken into consideration and flexible working times make it possible to balance work life and family life.”

Growing with item

Luyin joined item direct from her information technology course at Niederrhein University. She initially worked in the “Business Solutions” section, where she helped to develop the ERP solution Axapta. She was then presented with a very special opportunity when item took the strategic decision to officially distribute its own products in Asia in 2010.

Luyin currently works for item China in Qingdao, Shandong Province, where her main responsibilities are process management and market development. She also looks after core customers and is supporting the ERP rollout and optimisation of on-site business processes: “I like item because we get the opportunity to develop a whole range of skills in numerous areas during our career.”

How widespread is the lean philosophy in Germany? What are the biggest challenges when it comes to establishing lean principles? What trends are emerging in lean production?

Hello Mr. Döppler, in your view, how well established is the lean philosophy in day-to-day industrial operations in Germany?

Karl Heinz Döppler: There is still a great deal of variation across different sectors and companies. The lean philosophy has of course spread out from automobile manufacturing to automotive suppliers and then on to the investment goods, chemical, food and medical technology sectors. It has even been discussed at some level in offices and organisations in the public and healthcare sectors. But, let me put it diplomatically – the lean philosophy certainly plays a part in day-to-day industrial operations in Germany, but there is still a great deal of variation when it comes to individual companies making full use of its potential.

Why does implementing the lean philosophy pay off for both large companies and SMEs?

Döppler: Basically, the size of a company has no bearing on the effectiveness of the lean philosophy. Take one of the primary goals – eliminating waste: there is waste in all companies of every size. My own view is that small and medium-sized enterprises have an invaluable advantage – they can adopt new structures and decision-making processes much faster, which means they can also roll out the lean philosophy much faster and on a much broader basis.

What trends are currently emerging in lean production?

Döppler: I believe recent years have seen three primary developments emerge: 1. There has been a great deal of discussion in Germany – largely on an academic level – about the “Factory 4.0” concept, and some have been asking “Lean or Factory 4.0?” For me though, Factory 4.0 is simply a logical progression of the lean philosophy, but using different means. 2. The second trend we can make out at the moment is that lean principles are spreading to every part of the value-added process (end-to-end) – sales, order acceptance, logistics, production, delivery, etc. All parties are being involved and, as a result, the lean philosophy is gaining ground in administrative areas and even spreading to suppliers. 3. One development we have identified, particularly during coaching activities for lean roll-out projects, is that the human factor has to play an ever bigger role. Viewing a lean roll-out as simply a reproduction of the “Toyota methods” is rather counterproductive.

What do you think are the biggest challenges for establishing lean production and lean management in companies?

Döppler: Unfortunately, when it comes to establishing lean principles, introducing specific methods – such as 5S – simply isn’t enough on its own. The lean philosophy is an all-encompassing management concept and requires all levels in a company to rethink how they do things. The biggest challenge is therefore the human factor. Most companies find it unbelievably difficult to get their people to turn their backs on ingrained approaches and processes, adopt a new understanding of management and learn to identify and communicate problems so that they can then be totally eradicated.

Are there other example besides the automobile industry where the philosophy has been implemented successfully?

Döppler: The lean philosophy has certainly taken business by storm – there is hardly any sector or industry that is not working to avoid waste on a systematic basis. Nevertheless, the automobile and automotive supplier industries are still a step ahead, not least because they have been working with the lean principles for longer. I have a big problem with the second part of your question. So let me ask a question of my own: What is a successful lean roll-out? There are currently very few examples of genuine “lean factories”, i.e. companies that have implemented the lean philosophy throughout every aspect of their operations, from sales to dispatch and operational staff to the management board. And yet it doesn’t really matter whether a company has “finished” implementing lean “successfully”. What actually counts is whether or not a company or organisation has adopted the lean approach and is learning to find its own – hopefully more waste-free – way forward. I would imagine that not even Toyota itself would claim to have finished implementing the lean philosophy. 

Thanks for talking to us Mr. Döppler.

Production is production – how can it be lean? The debate about what exactly lean production is and isn’t has been raging since the late 1980s.

The evolution of lean production

John Krafcik was the first to coin the term “lean production” in his highly regarded 1988 article “Triumph of the Lean Production System”. To understand the benefits of lean production and why it has changed the world, we need to know more about it than just its principles and origin. We have to also take into account how industrial production has operated over almost a century.

We are going to examine this topic in two blog articles. The first part looks at the time before lean production and the second, which will appear subsequently in this blog, focuses on the lean philosophy as an alternative to centrally planned production, which was efficient to a certain extent, but not lean.

Taylorism – before lean production

An approach that is typical of Taylorism is to divide work processes into separate steps so that each can be centrally planned and optimised. Everything is precisely measured and analysed, such as how long it takes a worker to move a workpiece from the ground to a shelf. All this data is also used to analyse how specific processes can be made more efficient, so that a work bench can be restocked with materials at the same rate that they are being processed, for example. Everything is secondary to the overarching process. Deviations are undesirable – in fact, all the work steps are intended to interlock like gearwheels.

The conveyor belt as a feature of centralised production

In 1913, Henry Ford kick-started the most intense phase of the second industrial revolution when he introduced the concept of focussing consistently on processes. The conveyor belt became a symbol of the industrial age. Conveyor-belt production, standardised mass-market products and specialised machinery were seen as the best ways to drive down costs even further and make products affordable for more and more people.

The conveyor belt set the pace that all other processes had to follow. Deviating from the central plan was not an option – employees were to carry out only the one task from the entire process that had been assigned to them and do so quickly and carefully. Initiative was not encouraged.

However, some ten years after conveyor belts had revolutionised production forever, the first problems started to appear. While customers were increasingly demanding cars that were different, Henry Ford insisted in his book “My Life and Work” that: “Any customer can have a car painted any color that he wants so long as it is black”1. 

The manufacture of variants and ever shorter product cycles posed major challenges for the system of centrally planned mass production. When everything runs as planned, goods can be produced with maximum efficiency, but every change – and therefore every innovation – drives up costs.

Centralised planning and optimisation

Centralised process control reaches its limits when products and markets start to change rapidly. When operating a centrally planned system, making changes is a long, drawn-out and complicated process. Because the system needs to be planned as a whole, production is inflexible. That presented an opportunity for lean production, which we will be looking at in the second part of this article.