KEYSTONES BESPOKE AUTOMATION

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. 

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. 

Keystone Lintels achieves a remarkable 4.8 meters of lintels every 27 seconds, streamlining operations and boosting efficiency.

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.