Rethinking production

A start with vision

Handtmann Processing develops and builds systems for filling and portioning a wide variety of foods—from sausage and baked goods to pet food—at its headquarters in Biberach. The company supplies solutions for small businesses as well as fully automated systems for industry. Production manager Georg Briegel attaches great importance to line and process expertise as well as individual customization via a modular system. The plant in Biberach was built in 2000 and has been continuously expanded.

Most recently with the new assembly hall for vacuum fillers, which Handtmann has been developing since 1966. These machines convey and portion paste-like mixtures with gram precision and function as basic modules in integrated production processes. There are 14 models to choose from, which can be individually configured with standard and special options.

As part of comprehensive plant structure planning in collaboration with the management consultancy Staufen, a holistic location analysis and structure project was initiated. It forms the foundation for a manufacturing architecture that consistently implements lean principles while also offering scope for scalability.

“Without fundamental changes to our processes and structures, we would not have been able to further expand our market leadership,” says CTO/COO Dr. Mark Betzold. “A cornerstone of this change is the introduction of cycle assembly and the associated construction of the new assembly hall for our filling machines.”

Tactfully into the future

The approval of the new hall provided an opportunity to completely rethink the assembly process. A project team developed a concept based on a synchronized flow assembly line that allows for a wide range of variants.

The result: Structured work cycles, supplemented by upstream pre-assembly, now enable predictable, highly productive assembly with short throughput times. State-of-the-art conveyor technology and a well-thought-out provision of all necessary components ensure ergonomic working conditions and high added value. “Our previous assembly system had reached its limits,” explains Production Manager Georg Briegel. “With the new cycle principle, we can standardize processes, adapt them flexibly, and at the same time significantly increase efficiency.”

Set wagon instead of search game

At the heart of the new assembly logic is the so-called set trolley concept. Each assembly order is accompanied by an individually equipped trolley on which the necessary components are ready and waiting. This reduces travel times, prevents errors, and ensures clarity at every workstation. “Missing parts? Not anymore,” assures assembly manager Alexander Zinnecker.

Special attention was paid to the ergonomic design of the workstations and the integration of digital feedback systems (BDE). RFID chips store the order data and can be read at all stations. This ensures control and transparency at every single assembly step. According to Alexander Zinnecker, this makes work much easier: “Employees no longer waste time searching and waiting, which makes the entire work process more relaxed.”