Curbed ‘Roofing’ Manpower Dependence
Accelerated Production line
Setting The Scene
Keystone Lintel Limited, a leading manufacturer of steel lintels and roofing solutions. At their Derbyshire facility, they produce a wide range of lintel variations from high grade pre–galvanised mild steel with a zinc coating of 600g/m². With an extensive product line-up and a labour-intensive manufacturing process, the company faced challenges in terms of manpower requirements and energy consumption.
Optimised Operators Headcount per Line
Reduced Energy Consumption by Eliminating Welding
Elimination of Rework & Re-galvanising
Minimised Total Cost of Operations
The Challenge
Keystone Lintels produced 122 variations of lintels, with length varying from 750mm to 4.8m, material thickness from 1.6mm to 3.2mm, 3 cavity widths, 2 outer leaf lengths and 132 different types of insulation.
It required multiple production lines and extensive manual labour. This process involved shaping the lintels using press brakes and performing insulation fitting, welding, and galvanised painting. The existing production method demanded significant manpower and consumed substantial energy, hindering operational efficiency.
The Solution
To address these challenges, a semi-automated production line was developed, integrated with the existing automated press brake folding line. The new production line featured an insulation loading station, guided by screens that directed operators on insulation placement.
Two insulation presses ensured precise positioning of insulation within the lintel cavity. A break plate punch system transformed a steel coil into individual plates, which were then stacked and transported by a conveyor system to a pick and plate cell.
This cell picked the plates, performed necessary punching, and pierced the insulation in the lintel. The lintels continued through a roll forming station for perforations and outer lip formation before reaching the end of the line for operator offloading.
The Benefits
The new production line achieved remarkable outcomes for Keystone Lintels. With a production rate of 4.8 meters of lintels every 27 seconds, the line had the capacity to produce 6,665 lintels and 21,300 break plates in a 10-hour shift. The significant reduction in manual labour required to produce a single lintel was a key benefit, streamlining operations and improving overall efficiency.
The adoption of clinching technology eliminated the need for spot welding, reducing energy consumption and eliminating the necessity for post-galvanized coating. This resulted in cost savings and an improved workplace environment.
Optimised Operators Headcount per Line
Reduced Energy Consumption by Eliminating Welding
Elimination of Rework & Re-galvanising
Minimised Total Cost of Operations
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