The vacuum lifters from Schmalz have already been in use in other branches for a lengthy period of time and have impressed across the board there.∼ Production Manager Fuyao Europe GmbH
Schmalz Vacuum Lifter Optimizes Automotive Glass Production at Fuyao
At Fuyao Europe GmbH, a supplier of vehicle windows, vacuum lifters and crane technology from Schmalz create ergonomic working conditions for employees.
Features of the success story
| Industry | Glass |
|---|---|
| Workpiece | Automotive windows |
| Product group | Vacuum Tube Lifter JumboFlex |
| Type of handling | Manual Handling |
With Schmalz
50
kilogram
effortless handling
The customer: Fuyao Europe GmbH
Fuyao is a leading global manufacturer of automotive glass with Chinese roots. The Fuyao Glass Industry Group is headquartered in Fuqing, China, and produces raw glass for vehicle windows as well as complex glass elements. The German subsidiary Fuyao Europe GmbH has locations in Heilbronn and Leingarten and manufactures vehicle windows for European car manufacturers. The company attaches great importance to innovation and quality in automotive glass production and supplies a large number of well-known car manufacturers worldwide. With state-of-the-art production facilities, Fuyao strives to manufacture high-quality products and to take a leading position in the automotive industry by continuously improving its processes, while at the same time meeting the requirements of its customers.
The challenge
Fuyao needed a solution to optimize the work processes in the windshield production and to improve efficiency and safety. Before introducing the Schmalz solution, Fuyao relied on a manual process in which employees transported the windshields by hand using suction cups as gripping aids. This process was very physically demanding, as the windshields typically weigh between ten and 15 kilograms. The Fuyao employees had to lift the heavy panes out of the transport crates and place them on a rotatable rack. The lifting, lowering and positioning of the panes was all done manually. Preparing the windows for final assembly in the car factory was particularly challenging. After applying a special adhesive to the edge, the panes had to be carefully placed on a holder to enable the bonding process. This task not only required precision, but also placed a high level of physical strain on the employees. In addition, manual handling was inefficient and time-consuming. The production processes were not very flexible and could not be quickly adapted to changing requirements. Overall, the process prior to the introduction of the Schmalz solution was characterized by inefficient workflows and high physical strain.
The solution from Schmalz
Schmalz's solution for Fuyao consists of five JumboFlex vacuum tube lifters and cranes specially designed to meet the requirements of pane production. These are strategically placed in the production hall to optimize the workflow and increase efficiency. The JumboFlex vacuum lifting devices are equipped with powerful vacuum pumps that enable reliable and fast handling of heavy windshields. The suction cups are made of high-quality nitrile rubber (NBR), which ensures safe and gentle gripping without damaging the surface of the windshields. In addition, the suction cups are provided with a protection cover to avoid possible marks on the glass. The Schmalz cranes have an impressive jib length of six meters and a slewing range of 270 degrees, so that employees have sufficient freedom of movement to position and handle the panes precisely. In addition, the cranes are equipped with silencer boxes to reduce sound levels during operation and thus create a more pleasant working environment. Schmalz's overall solution for Fuyao aims to optimize windshield production workflows, ensure employee safety and increase production capacity.
An employee prepares the pane for gluing.
The pane is placed on a swivel gantry with four suction cups for the final inspection.
Positioning the windshield to fix the sealing gasket.
Special covers for the suction cups protect the sensitive glass surface from marks.
Customer benefits through the Schmalz solution
Increased efficiencyEasier handling of vehicle windows leads to higher production speed and efficiency
ErgonomicsMinimizing workload and creating an ergonomically sound working environment
PrecisionOne-finger control and precise load positioning improve product quality through exact placement of the vehicle slices
Products used in the application
Vacuum Tube Lifters JumboFlex Generation 1
- JumboFlex for ergonomic one-hand operation for fast movement sequences
- Configurable lifting unit, operator handle, vacuum gripper and vacuum generator
- One-finger / two-finger control for right-handed and left-handed users
- For workpieces up to 50 kg
Column-Mounted Jib Cranes
- Fitted with anchors for floor mounting
- Lift capacity up to 1,000 kg
- Optionally with mobile base plate (lift capacity up to 200 kg)