The laboratory technology provider Thermo Fisher Scientific has developed an ergonomically designed production line for the manual assembly of incubators.
Apart from the health-conscious workstation design, the priority was on process and product quality. Time and cost arguments followed only in second place.
The "Heracell Vios" incubators are intended for medical engineering and health research, where they are used for cultivating human and animal cells. Numerous variants for different applications are assembled in the plant at Langenselbold near Frankfurt. Apart from two sizes with 160 and 240 litres of useful space, bactericidal and fungicidal models of copper are available in addition to incubators with a stainless steel inner container, and the portfolio also includes incubators for different gases and with varying sensor technology. According to Thermo Fisher, the company is the global market leader in the product field.
In order to prepare production, Felix Pergande, Technical Head of Production for Thermo Fisher Scientific in Langenselbold, and Production Resources Engineer Stefan Kämmerer first developed a prototype of the assembly workstation. Subsequently, they used this do developed a new series production line which resulted in a "start-up plant". Pergande explains what this means: "During this period of about half a year, we have the overall responsibility for the incubator production, from organization and material procurement through to quality assurance. We industrialise production in this time. As soon as it is well engineered, we hand it over to the responsible people in the Incubator department.
In the development of the assembly workstations, Thermo Fisher Scientific cooperated with ROEMHELD experts for assembly and handling technology. The ROEMHELD moduhub program comprises numerous modules that can be used to create safe, ergonomic positions for objects in manual assembly. Moduhub comprises a modular system with application flexibility and variably combinable components for loads from 10 kg to 600 kg; which can be operated electrically or alternatively manually.
Pergande is very satisfied with the cooperation: "ROEMHELD's consultation quality is extremely high, they intensely and dedicatedly respond to our individual requirements. In addition, their products are very reliable and can be configured according to our requirements - we do not have to buy anything ready-made."
As regards the conception of the new manual assembly workstation, ergonomics were of particular significance to Production Resources Engineer Stefan Kämmerer. For the earlier incubator series had indeed been assembled on heigh-adjustable tables, but the units with a weight of around twenty kilogrammes had to be moved manually without any auxiliary equipment. "For this reason, preassembly of the inner containers required a lot of handling and was physically more demanding", says Kämmerer. This had to be improved for the production of the new series.
The inside casing which is open to the front has a height of approx. 700 mm and a width of 450 mm for the 160-litre incubator type and is manufactured in Thermo Fisher's own sheet workshop. In preassembly, an employee covers all five sides with heater foils; for this purpose, the container has to be rotated several times. Apart from this, a sensor and a fixture have to be mounted. The entire process takes about 45 minutes; subsequently, insulation is attached and the outside casing is assembled over it. The site in Langenselbold has around 150 assembly employees, of whom eight are assigned to the manufacture of incubators, in one or two shifts as required.
With the support of ROEMHELD, Kämmerer and Pergande designed a line of four similar assembly workstations arranged successively. The workstations are designed to accommodate all necessary incubator models.
All workstations comprise an electronic Shop-Floor lift module with a stroke of 200 mm, which can be lifted and lowered by a pushbutton, and a rotary module. This rotary module is provided with indexations which may be released manually in steps of 45°; for this purpose, the fitter can use two foot switches without having to walk around the longitudinally arranged container. "The prototype of the assembly workstations had only one foot switch. In order to be able to work more efficiently, the fitters had the idea of a second foot switch; this suggestion could rapidly be implemented by ROEMHELD", Kämmerer remembers. After the design of the assembly workstations was completed, he ordered the components from ROEMHELD and assembled them.
All parties involved are satisfied with the result of the workstation design. Technical Head Felix Pergande emphasizes the excellent ergonomics and sees an evident improvement in product quality: "The clear position fixation and the defined handling by means of the 45° indexations noticeably reduced the risk of dents in the container." According to him, time saving as frequently experienced after the optimization of other assembly workstations is no goal in this case. Reduced cost were not calculated. However, he emphasizes that the ergonomic design of the workstations contribute to protecting the employees' health and that "the absence of an employee costs money, because either we cannot produce or we have to assign a replacement." As a consequence, less rejects and healthier employees contribute to cost savings and enhance Thermo Fisher's success as market leader.
The preassembly staff also has positive things to say. Equipment fitter Steffen Hillesheim compliments: "An ergonomic workstation with useful features like this is invaluable. It is good for the back, neck, and shoulders and is a noticeable relief. The body feels it immediately." Hillesheim knows what he is talking about, since he has been working for Thermo Fisher for a few weeks only and says he has gained a lot of experience on assembly workstations not complying with the latest occupational health and safety regulations.
For the planning of future assembly workstations the standard interface conception of the moduhub programme is very helpful. Because it allows for the flexible and uncomplicated planning of future workstations.
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