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Series assembly of drive and guide units

How Zettl ensured stable quantities over several years and made reliable series processes possible for a machine manufacturer

A man wearing gloves and dark work clothes uses a wrench to adjust guide units in a brightly lit industrial hall.

Initial situation

A mechanical engineering company for conveyor systems needed a reliable partner who could deliver standardized drive and guide units permanently and reproducibly pre-assembled. The quantities were higher than the customer's internal capacities, which led to bottlenecks in series production.

The challenge

The assemblies consisted of motor mounts, roller packs, bearing housings, covers and pre-assembled sensors. The decisive factors were precision, repeat accuracy and the ability to deliver high quantities consistently over many years - without fluctuations in quality.

Solution

We set up a specially adapted assembly area, including incoming goods inspection, ergonomic workstations and a digitally controlled inspection process. Each assembly was mounted, lubricated, tested and documented with a serial number in accordance with defined tolerances.

Result

Production could be supplied stably over several years. Our structured series production process led to reliable supply chains, fewer capacity bottlenecks at the customer and a noticeable reduction in internal process costs.

Conclusion

Several years of stable series supply

High repeat accuracy thanks to documented processes

22 % lower process costs thanks to external series assembly

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