Furniture Factory Automates Production:

ABC Reoler Accelerates Growth with Robot Solutions from Manomatic

ABC Reoler, a part of the Danish Furniture Group, has taken a crucial step towards growth and success by implementing robot solutions from Manomatic. These advanced robots play a central role in the realization of ABC Reoler’s growth strategy.

In collaboration with Nicholaisen A/S, Manomatic has delivered customized robot solutions to ABC Reoler in Aulum. These robots constitute the heart of the company’s palletizing processes, which are crucial for efficiency at the end of the production line.

The chosen solution is based on Manomatic’s expertise and includes reliable and advanced KUKA robots. These robots are designed to handle ABC Reoler’s specific needs and requirements, including the handling of shelves and wooden boards for their renowned shelving concepts Quadrant and ABC Classic.

“With the latest two ‘end of line’ solutions, we are now ready to face the market,” says Henrik Østergård, who was hired as the production manager two years ago.

The goal is to increase turnover tenfold

He is in the midst of a five-year turnaround at the Aulum factory, where one of the objectives is to increase growth from 10 million Danish kroner to 100 million Danish kroner.

“The factory is now fully automated. This also means that we have completed the biggest investment, so now production just needs to ramp up,” he explains, adding:

“A robot is a lifelong friend. Employees are no longer worn out, and they come to work happier. It’s a win-win,” says Henrik Østergård, who is not concerned about humans becoming redundant as labor.

Carpenter Jeppe Goul has been very satisfied with the collaboration with Manomatic during the commissioning of the robot cells: “If there have been any issues, most of it could be resolved over the phone or through guidance on the tablet. Manomatic has been there when they, along with Nicholaisen and other suppliers, needed to commission the production equipment. Having a good supplier team and the ability to collaborate are crucial,” says Jeppe Goul.

Production Manager Henrik Østergård is working on reducing costs and increasing productivity.

– With the latest two ‘end of line’ solutions, we are now ready to compete in the market.

 

The vacuum gripper’s various suction cups ensure stable handling of the MDF boards.

The Solution

The robots are equipped with a vacuum multi-grip system, ensuring high dynamics and operational reliability during depalletization, as well as gentle handling of shelves and boards.

A vacuum timeout function ensures minimal air consumption. When the production line stops, the robot places the items back on the pallet and returns to its starting position. When the line is ready again, the robot automatically resumes operation.

To handle the significant variations in the quality of MDF boards, the gripper is equipped with a variable vacuum suction and a two-step lifting function, ensuring stable depalletization of MDF boards.

In one fully automated system, 16 shelves are lifted and moved per minute. The robot lifts three shelves at a time from a pallet and transfers them onto a conveyor belt. The robot can easily lift and move 3000 shelves per day, equivalent to approximately 17,000-18,000 shelves per week.

The robot is set to search for the height of the shelves. To ensure vacuum ejectors operate reliably with the lowest possible air consumption, the robot picks up three shelves at a time using an integrated vacuum gripper and springs.

The palletizing systems are operated intuitively and flexibly through an integrated touch user interface with Manomatic’s user-friendly interface, allowing the operator to create or modify pallet patterns.

Customer: Nicholaisen/ Danish Furniture Group
Industry: Furniture Manufacturing, Panel Industry
Projects: 2 Robot Cells for palletizing wood panels and MDF panels.

Manomatic’s intuitive and flexible HMI (Human-Machine Interface) makes the operator’s daily tasks easier.