Increasing capacity and efficiency via hybrid automation at Pantor

Company overview

Pantor is a leading manufacturer in the joinery sector, specialising in the assembly of high-quality door systems. With a commitment to innovation and operational excellence, Pantor continually seeks to enhance its production capabilities and workplace standards.

Executive summary

The implementation of hybrid automation has delivered substantial benefits, including:

• A significant increase in production capacity, with the ability to produce up to 115,000 units per year.
• A streamlined, integrated production flow that leverages the strengths of both automation and manual processes.
• Improved operator safety and comfort, thanks to ergonomic enhancements and reduced manual handling.

Project objectives

To support growth and meet increasing market demand, Pantor launched a project with the following main objectives:

• Increase the production line capacity to 115,000 units per year.
• Integrate multiple technologies into a seamless production flow.
• Improve the ergonomics of operator workstations.

The challenge

The existing door assembly process faced limitations in both capacity and efficiency. Manual handling of sheet metal, gluing, assembly, and pressing processes constrained throughput and introduced ergonomic challenges for operators. Pantor required a solution that would not only boost output but also streamline operations and improve working conditions.

The solution

A hybrid automation approach was adopted, combining advanced automation with optimised manual processes. The new system was designed to:

• Automate key processes, including sheet metal handling, gluing, assembly, and pressing, to ensure consistent quality and higher throughput.
• Integrate multiple technologies into a unified, seamless production flow, minimising bottlenecks and manual interventions.
• Optimise manual tooling by introducing automatic turntables, thereby improving efficiency and reducing operator fatigue.

Key achievements

Increased production capacity

The production line now operates with a 60-second tact time, supporting an annual output of up to 115,000 units and enabling Pantor to meet growing customer demand.

Hybrid automation

By automating critical processes while retaining optimized manual operations where appropriate, Pantor has achieved a balanced approach that maximizes both efficiency and flexibility.

Enhanced ergonomics and efficiency

The introduction of automatic turntables has significantly improved the ergonomics of operator workstations, reducing physical strain and supporting a more efficient workflow.