PREDIMO – Analysis and Optimization at Suttner

PREDIMO for investigation and optimization at Suttner

Predimo is not only the only institute in Europe that is authorized to certify exoskeletons for industrial use. They also operate the largest crash test facility and are the most renowned institute for accident reconstruction.

For a few years now, Predimo has been using its know-how to investigate and optimize workplaces in production, assembly and logistics.

It works like this:
The employee is equipped with 12 sensors (3 on each arm and 3 on each leg). His movements are reproduced as a digital image on the computer. You can actually see how the avatar on the screen moves exactly the same way as the colleague in real life. Then it starts. The employee begins his normal daily business and all movements are recorded. The data recorded over the entire period of a customer order, for example, is passed on to an AI program that carries out an initial automatic analysis using everything it has learned so far. This is divided into two large complexes:

• Evaluation of ergonomics
• Allocation and evaluation of the individual movements belonging to the process

Predimo’s experts evaluate these results and supplement their analyses with recommendations for quick or fundamental optimizations.
The evaluation of ergonomics leads to the point where it is possible to predict very precisely how likely non-ergonomic movements are to cause health damage. Accordingly, less “good” processes are shown in yellow or red. The assembly process at Suttner is not affected by any health-endangering processes. However, it has been found that height-adjustable tables and ergonomic sitting and standing aids are a good improvement. What was much more exciting for Suttner was the part of evaluating the timing of process steps. All permanent staff members took part in the tests and almost all assembly stations and most important products were checked.

We have gained very valuable results from this part of the study::

The results at a glance:

• Support of assembly through extended logistics support
• Reduction of non-productive times
• Expansion of buffer areas
• Optimization of plant operation
• Reduction of downtime

Suttner has decided to invest in new equipment for the assembly stations to optimize processes in four assembly areas (turbo nozzles, double lances, swivel, spray gun assembly) before moving to Lemgo.
We want to reach an agreement with the specialist Predimo that will give us the opportunity, even after completion of the project and relocation to Lemgo, to simulate the further development of the assembly using plans that are based directly on the analysis results.