项目背景
Anadolu Asansör A.Ş. manufactures elevator cabin panels, door frames and sheet metal enclosures in Istanbul, supplying assemblers across Turkey, the Middle East and Eastern Europe. The company produces roughly 900 cabin sets a year from a mix of about 250 panel and frame part numbers.
Panels were cut on a 4 kW laser, but the frames were TIG welded by hand in a separate area — 25 to 30 minutes per frame — and the finish on the cut edge was done by hand with a wire brush on a polishing wheel, which was the single most inspected characteristic on the cabin.
Edge finish was why a lot of the work went out. Roughly a fifth of panel orders were bought from a subcontractor because the customer would not accept the in-house brushed edge, and the freight and lost margin on those orders was substantial.
Cycle time on a standard 900 mm cabin set was 6 hours 20 minutes end to end, and the plant ran 40% over its quoted lead time on customised jobs.
客户挑战
Hand TIG welding of frames took 25 to 30 minutes each and needed a welder who could read a fit-up drawing. Two of the three welders left within a year, and the department was never able to staff a third shift.
Hand brushing of the cut edge was 9 minutes per panel and inconsistent — the quality department rejected about 8% of finished panels for edge finish alone, and those were then re-brushed.
Outsourced panel orders cost the company roughly 40% of the premium over in-house pricing, with a two-week lead time, which was the reason customised jobs slipped past their promised date.
The plant could not add a welding robot without a stable volume of the same frame, which it did not have, because every order customised the frame slightly.
解决方案
Anadolu installed the LP-W2000-3kW as a dedicated laser welding cell on the frame line. Frames are fixtured on a rotating positioner, the programme is imported from the same CAD package used for the panels, and the operator loads, starts and moves to the next fixture while the seam runs.
An LP-F1503-3kW was installed for the panels, replacing the older 4 kW machine, with the key change being the handling and the edge strategy rather than the source alone. Panels are nested across the whole open order book rather than job by job, and the cut edge is finished with a light, consistent pass that replaced the hand brushing station.
The CAD library was reorganised so that the panel blank and the frame share one parametric definition, which meant a change to the cabin size propagated automatically to both the cut and the weld programme. That eliminated the class of error where a modified blank reached the weld station with the original frame programme.
Two robots were also deployed on end-of-line handling for finished panel stacks, removing a manual step that was the second-largest labour item after welding.
交付成果
Frame weld time fell from 28 minutes to 9 minutes 20 seconds, an improvement of 67%, and the cycle no longer depends on a coded TIG welder. The cell is currently staffed by one operator who also handles the panel load position.
Panel edge rework fell from 8% of finished panels to 4.5%, and both outsourced panel suppliers were dropped at the end of the first quarter, bringing roughly 120 orders a year back in-house.
Overall cycle time on a standard 900 mm cabin set dropped from 6 hours 20 minutes to 4 hours 5 minutes, and the plant brought customised-job lead time from 40% over the quoted window to within 5%.
Material yield rose 3 percentage points through cross-order nesting, and the manual brushing station — with its dust extraction and four operator hours per shift — was removed from the building.
The business has since won two new export framework contracts that the previous lead time would not have supported.