The production of laminate covers was time-consuming and did not guarantee repeatable details. The customer needed a solution that would speed up production and improve the quality of the parts. By using thermoforming, we eliminated the problems of manual production, significantly reduced lead times and ensured the highest quality. What did the transformation look like? Check it out!
CUSTOMER PROBLEM:
🔸High weight of covers: The laminate used for agricultural machinery covers was relatively heavy, which affected the weight of the entire machine.
🔸Lack of repeatability of details: Handmade laminate covers meant that the details were not identical, which reduced the quality and consistency of the product.
🔸Time-consuming production process: The production of laminate covers was long and consisted of manual application, sanding and machining, which increased lead times.
🔸Need to change technology: The customer was looking for a solution that would improve quality, increase production efficiency and reduce the weight of the covers.
SOLUTION:
✅ We used thermoforming: Instead of laminate, we suggested using thermoformable plastic, which is lighter and more resistant to damage.
✅ We have increased the repeatability of production: Thanks to thermoforming, we have ensured identical shapes and uniform detail quality, which has completely eliminated the problem of differences between individual parts.
✅ We have reduced production time: Thermoforming process is much faster than traditional manual production of covers, which has significantly reduced lead times and increased production efficiency.
✅ We have increased the durability of the covers: The new shields show greater resistance to mechanical damage and weathering, making them more durable and reliable in harsh working conditions.
✅ We used modern machinery: Thanks to modern thermoforming machines, which enable the molding of large parts, we have been able to meet customer requirements and realize production according to their expectations.
Want to learn more about how our solution has impacted functionality and production efficiency?
Keep reading to learn more about this realization!
Who was the customer?
The client is a manufacturer of agricultural machinery that seeks to increase the production efficiency of its newly designed machines, as well as significantly improve their functionality.
In this case, the manufacturer was looking for an effective solution to streamline the production of side covers for the new machine model, reduce the weight of the side covers, and improve the quality and durability of the finished product.
What problem did the customer face?
🔸High weight of covers
Shields made of laminate were heavy, making them difficult to install and remove, increasing service and maintenance time for the machine.
🔸Lack of repeatability of details
Handmade laminate covers meant that the parts were not identical, which reduced the quality of the final product. Differences in details could also lead to difficulties in assembly and affect the appearance of the machine.
🔸Time-consuming production process
The process of manually applying the laminate, sanding and machining the parts was very time-consuming, increasing the lead time. This in turn affected overall production efficiency, delaying the launch of the machines.
🔸Need to change technology
The customer was looking for a solution that could streamline production, reduce the weight of covers and ensure better quality. A change in technology was needed to meet growing market demands and improve product competitiveness.
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Solution designed by Geo Globe Poland
To solve the above problems, we proposed application of thermoforming - modern production technology, which allowed the rapid and precise production of large shields with identical shapes and high durability.
In order to effectively solve the customer's problems, we proposed the use of modern thermoforming technology, which makes it possible to quickly, precisely and efficiently produce large shields with high durability and identical shapes. Originally manufactured from laminate covers, which were relatively heavy and subject to mechanical damage, were replaced by thermoformed plastic. This material proved to be lighter and more resistant to harsh operating conditions, which significantly improved the functionality and mobility of agricultural machinery.
Thanks to the use of thermoforming, covers produced using this technology were uniform in terms of details - eliminating differences in individual components that could affect the quality of the finished product. This process ensures high repeatability and precision, which is crucial in the production of agricultural machinery, where consistency and quality of details are of great importance. In addition, thermoforming has made it possible to significantly reduce production time. The traditional process of manufacturing laminate covers, which required manual application, grinding and machining, was very time-consuming. Application of thermoforming has streamlined the entire process, reducing lead times and enabling faster delivery of machines to customers.
The new covers also feature greater resistance to mechanical damage and weathering. As a result, they were more durable and reliable, a key improvement in terms of the operating conditions of agricultural machinery. Thanks to our state-of-the-art machinery, with advanced thermoforming machines, we were able to mold large-size parts, thus meeting customer requirements for quality, quantity and timely production.
Technical parameters of the fence:
🔸Above-ground height: 50 cm - ensuring effective security of the site against unauthorized access.
🔸Pile: 10 cm - a structural reinforcement element that affects the even distribution of loads.
🔸Beam width: 20 cm - allowing easy and quick installation and removal, while maintaining high strength.
🔸Depth of the slab in the ground: 10 cm - guaranteeing the stability of the entire structure, even under varying ground conditions.
🔸Depth of the post in the ground: 50 cm - to ensure firm seating of the fence, which minimizes the risk of displacement or deformation of the structure.
🔸Additionally, we used innovative connection solutions - a system of sealed connections with a culvert and U-turn terminations of the sections resulted in a protective barrier that is both functional and aesthetically pleasing.
The end result - what did the customer gain?
Through the use of thermoforming, the client has achieved significant benefits in several key areas:
- A lighter machine
Reducing the weight of the guards affected the ergonomics and mobility of the machine.
- Consistency of production
Thanks to thermoforming, all covers were identical, improving the quality of the final product and streamlining machine assembly.
- Faster order processing
Reduced production times allowed the machines to be brought to market faster, increasing production efficiency and reducing production wait times.
- Greater resistance to exploitation
The new shields also showed higher resistance to weather and mechanical damage, which increased their durability and ensured the reliability of the machines in harsh working conditions.
- Better quality
Thermoforming process ensured consistent quality and repeatability in production, eliminating problems associated with variations in details, which directly affected the quality of the overall product.
By implementing thermoforming, the customer has achieved significant benefits both operationally and cost-wise. Its machines are now more functional, lighter and easier to manufacture.
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