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Prima power

Prima power

Prima power

Case: Prima Power – Jucat’s robotic system boosted the efficiency of a new automated production line

A client of Prima Power’s had long experience in manufacturing self-service storage doors manually. However, the manual process was afflicted by various challenges pertaining to internal logistics, leading to misplaced goods, delayed deliveries and even damaged products. It was clear that a more efficient, higher quality production system was required.

Prima Power delivered its client a new automated production line which required a robotic system for joining and attaching the door components. According to Antti Kuusisaari, Vice President of System Sales at Prima Power, Jucat was a natural choice for a partner as he was already familiar with the company which is located just a stone’s throw from Prima Power’s premises.

“I’ve known both Jucat and CEO Jukka Rintala for a long time. I knew Jucat is a highly dynamic and forward-looking company that has solid expertise in robotics and actively takes on new challenges. We inquired whether they could implement the robotic system we required, and that sparked our collaboration”, Kuusisaari recounts the early stages of the project.

Prima power

Automated production line implemented with Jucat

The companies’ collaboration launched vigorously. As the year was closing in and the Christmas rush about to hit, the tender had to be drawn up without delay. Prima Power outlined the initial information with high precision, enabling Jucat to respond very quickly. At first, Jucat created a simulation of the solution to be produced, focusing on improving production rate, among other things. The simulation convinced the client, and the production was started.

The initial stages of the production line were tested and demonstrated with the help of visualisations provided by the client. Then Jucat was provided with pre-bent door blanks to enable hands-on familiarisation with the components’ shape, size, weight, rigidity and other properties essential in terms of production. The next stage was to take a closer look at Jucat’s concept design, the scale of the solution and the content of delivery.

The production line was first assembled at Jucat’s production facilities where it was tested, inspected and pre-approved. After the robotic system had been adjusted to reach the desired output, it was re-assembled at the Prima Power factory where the client carried out the factory approval tests. The client was highly satisfied with the result: it met all the set criteria.

“Installation in the client’s country of manufacture is currently underway. Prima Power’s production line is installed first, and Jucat’s robotic assembly line will be fitted immediately afterwards. Then the system will be operational, and the client can start production. Upon completion, warranty service for the production line will be provided by the local ABB unit. In this project, Jucat’s good connections to ABB provided significant added benefits to our client”, Kuusisaari sums.

Added value to collaboration from professional project management

As a whole, the collaboration with Jucat was seamless, precise and effective. Communication was excellent throughout the project, and the proximity of the partners’ offices improved it further.

“As tailored projects are sensitive by nature, they have to be mutually monitored. Jucat’s project manager showed admirable expertise and initiative throughout the project. We were always aware of the project’s progress. Each question was answered immediately and every matter handled effectively and with expertise. For instance, at the final stretch of the project, the client got a development idea concerning the mounting of the system. Jucat grasped the idea quickly, and it was quickly implemented”, Kuusisaari states on the collaboration with Jucat.

 

Increased demand for turnkey automated solutions

 

The 27 metres long production line delivered as a turnkey solution contains all the components, equipment and machinery required for punching, bending and assembling door blanks. According to Kuusisaari, the project was extremely inspiring as the demand for automated production lines as turnkey solutions such as this is very high both in Finland and abroad.

“We constantly present and sell automated systems in the international market, and we get more and more inquiries on turnkey solutions. Clients have production-related requirements, challenges or ideas to which they search comprehensive solutions that cover the entire process from the raw material to the installed product,” Kuusisaari explains on the market situation of automated solutions.

Valtra

Valtra

Valtra

Automated production line

VALTRA is the leading manufacturer and service provider of tractor for agricultural use. The company develops, markets and produces high quality Valtra tractors and maintenance services as well as, other services in co-operation with its partners that provide value to its customers.

Valtra

The challenge

Valtra decided to start producing an assembly component at its own factory, which had previously been produced by a subcontractor. The company did not have previous experience in the manufacture of the component, and needed to develop a progressive production line that improved the company’s competitiveness. In addition, the line had to both produce a consistent quality and be efficient.

Our solution

We designed and implemented a turnkey automated production line for Valtra. We designed in co-operation with the customer a detailed and comprehensive concept design of the production line. We calculated a production capacity estimate for the production line that we committed ourselves to by giving the customer a productivity guarantee.

We implemented a progressive production line for Valtra based on our concept design, which fully took advantage of modern automation technology. The customer received a balanced solution that ensured consistent quality of production and improved competitiveness of the company. We meet the customers’ tight timetable, responded flexibly to changes and achieved the set production efficiency targets in full.

Ponsse

Ponsse

Ponsse

Multiple-robot welding unit for demanding needs

Ponsse Plc is a company specialised in the sales, production, service and technology of forestry machines for the cut-to-length method.

Ponsse

The challenge

Ponsse’s current range includes approximately 15 welded frames, the production of which the company wished to improve. For this purpose, Ponsse required a robotic unit comprising a workpiece positioner and a welding robot.

Our solution

After examining the frame welding positions, we came to the conclusion that the best option would be a portal robot with a positioning table. We designed a multiple-robot welding unit that was to be able to weld the frames of all harvester heads and any related components within a single station.

The workpiece positioning robot was scaled based on the torque caused by the worked object.

The robot’s software options were examined carefully. In addition to price, we compared the programming method, sensor data and programming environment restrictions.

We knew that designing and assembling the equipment was a challenge, but with a domestic manufacturer, the whole process progressed smoothly.”

Škoda Transtech

Škoda Transtech

Škoda Transtech

Manual production line

TRANSTECH Transtech Ltd is the leading European manufacturer of rolling stock for demanding conditions and an important contract manufacturer of mid-weight engineering workshop products. The company´s office is located in Oulu and works in Otanmäki, Finland.

Škoda Transtech

The challenge

Transtech planned to start producing trams’ at the Otamäki factory, and consequently needed a reliable turnkey solution provider for the investment. The aim was to combine a fluent manufacture of modern trams, work place safety and a ergonomically optimized working environment.

The new production process deviated from existing processes since it was heavily based on sheet metal manufacture, and Transtech did not possess as much experience in sheet metal as in heavier steel manufacturing. As a result, the production line provider needed to have extensive experience and know how also in this field.

Our solution

We produce a detailed plan of the complete production line in co-operation with the customer. This included everything from conceptual design, process descriptions, monitoring of implementation to management of work, all completed on schedule. As a result, we were able to design a balanced and efficient production process suitable for detailed work performed on the production line. Finally, the safest and most ergonomic tools where chosen for each stage of the production process.

Even if large structural changes were made to the planned final product, we managed to implement an efficient competitiveness enhancing production line. This was made possible by our mutual project management expertise and excellent co-operation. The customer was particularly impressed by our technical know-how and professional project management skills. We kept what we promised.