All Creative’s goal was to free the operator at their Zünd Cutter, so he could work on other jobs on multiple machines simultaneously. This achievement became reality by implementing a robot-based solution to automate their operations, benefiting both the worker on the shop floor and the company’s overall financial performance.

All Creative manufactures imaginative displays, packaging, and POS solutions for a diverse clientele. They operate production facilities in Vejle and Havndal, along with a sales office in Herlev. In their Vejle production site, they specialize in working with cardboard and corrugated paper, providing services such as digital printing, die-cutting, and digital cutting.

For smaller batches or one-time productions, as well as for very large sheets, they utilize their Zünd G3 XL-3200 digital cutting machine. It’s also employed to cut components for displays, among other uses.

The machine’s flexibility opens up numerous possibilities.

All Creative’s goal was to free the operator at their Zünd Cutter, so he could work on other jobs on multiple machines simultaneously. This achievement became reality by implementing a robot-based solution to automate their operations, benefiting both the worker on the shop floor and the company’s overall financial performance.

All Creative manufactures imaginative displays, packaging, and POS solutions for a diverse clientele. They operate production facilities in Vejle and Havndal, along with a sales office in Herlev. In their Vejle production site, they specialize in working with cardboard and corrugated paper, providing services such as digital printing, die-cutting, and digital cutting.

For smaller batches or one-time productions, as well as for very large sheets, they utilize their Zünd G3 XL-3200 digital cutting machine. It’s also employed to cut components for displays, among other uses.

The machine’s flexibility opens up numerous possibilities.

  • All Creative acquired a Zünd G3 XL-3200 digital cutter in 2016.

  • In 2022, they had an automation solution installed, which consisted of an ABB robot, a conveyor transport system, and an ‘eye-in-the-sky’ load table.

  • The system is set up for seamless production, moving materials directly from one pallet to another. The robot lifts and separates the sheets onto the EIS Load Table, which employs camera technology to identify jobs using barcodes and registration marks before transferring them to the cutting area.

  • Unloading is done using vacuum plates that securely hold all the freely cut parts, placing them neatly and stacking them on the ‘output pallet’.

All Creative’s competitive edge lies in efficiency and excellent customer service

We’ve met with Production Manager and Partner Michael Andersen and Production Manager Jan Thisted to discuss automation, flexibility, and competitiveness.

“When did you decide to automate your production and why?”

Jan Thisted, Production Manager

“It’s something we’ve been working on for a really long time.

Previously, we had a man locked to the cutter all day, who did nothing else but put boards on and take them off again. Had it been a more specialized function, it would have been something else. But in this case, it was a function that could easily be automated.

We discussed several solutions. Among other things. whether we could use a Board Handling System. But because we do a lot of backside cutting, it was necessary to find a solution that also included registration technology from below.”

Michael Andersen, Production Manager:

“For us, the clear path forward is automation.

We’d ideally like our machines to run 24/7, so we can provide our customers with quick deliveries and a great deal of flexibility.

We’ve wanted to improve the automation of our cutting table for quite a while, and a few years ago, we really began to dive into it. However, there are no ready-made automation solutions in the market for our very specialized and niche industry. Therefore, we had to create a custom solution tailored specifically for our needs.”

Jan Thisted, Production Manager

“It’s something we’ve been working on for a really long time.

Previously, we had a man locked to the cutter all day, who did nothing else but put boards on and take them off again. Had it been a more specialized function, it would have been something else. But in this case, it was a function that could easily be automated.

We discussed several solutions. Among other things. whether we could use a Board Handling System. But because we do a lot of backside cutting, it was necessary to find a solution that also included registration technology from below.”

Michael Andersen, Production Manager:

“For us, the clear path forward is automation.

We’d ideally like our machines to run 24/7, so we can provide our customers with quick deliveries and a great deal of flexibility.

We’ve wanted to improve the automation of our cutting table for quite a while, and a few years ago, we really began to dive into it. However, there are no ready-made automation solutions in the market for our very specialized and niche industry. Therefore, we had to create a custom solution tailored specifically for our needs.”

“Why did you choose Zünd?”

“Jan had worked with Zünd before, and he spoke highly of them, so it made sense to reach out to them.

They conducted the process very professionally. We’ve been engaged throughout, from the idea stage to the planning and beyond.

The installation of a solution like this is a learning process for both us and Zünd. We’re constantly working together to solve the issues that inevitably come up with a new system.

We receive quick responses to our inquiries, and the level of support is what you’d expect when implementing such a high-tech system.”

“One of the major benefits of Zünd is that they’re a smaller company with a ‘hands-on’ approach, and the fact that they’re right nearby is quite convenient.

Zünd has built a very strong reputation, and that gives us a very high level of trust in their capabilities!”

“Jan had worked with Zünd before, and he spoke highly of them, so it made sense to reach out to them.

They conducted the process very professionally. We’ve been engaged throughout, from the idea stage to the planning and beyond.

The installation of a solution like this is a learning process for both us and Zünd. We’re constantly working together to solve the issues that inevitably come up with a new system.

We receive quick responses to our inquiries, and the level of support is what you’d expect when implementing such a high-tech system.”

“One of the major benefits of Zünd is that they’re a smaller company with a ‘hands-on’ approach, and the fact that they’re right nearby is quite convenient.

Zünd has built a very strong reputation, and that gives us a very high level of trust in their capabilities!”

“The ABB robot was installed in January 2022.

The installation itself took around 3 days, following which the cutter could get back to work, this time with an automated companion.

In their Havndal facility, they have been using robot technology for 15 years, although on a smaller scale.

However, when it comes to the tasks assigned to the Vejle robot, it’s clear that “bigger” is unquestionably “better!”

“When do you expect full return on investment?”

“We’ve estimated that the system will have paid for itself in about two years and will effectively save us nearly one full position.

Surprisingly, only a couple of weeks after the installation, we’ve already reduced our workforce needs by half, and we’re quite happy about that.

The whole arrangement is reasonably priced, which makes us open to doing it again. From our perspective, this investment is very rational when considering the returns.”

“By including the robot on the cutting table, we make better use of our cutting capacity. So, the robot’s price is not as important because it quickly pays off when our existing cutting table becomes more efficient.

The machine is meant to cut around the clock without needing someone to operate it.

Every unmanned hour we can produce is bottomline profit for us.”

“We’ve estimated that the system will have paid for itself in about two years and will effectively save us nearly one full position.

Surprisingly, only a couple of weeks after the installation, we’ve already reduced our workforce needs by half, and we’re quite happy about that.

The whole arrangement is reasonably priced, which makes us open to doing it again. From our perspective, this investment is very rational when considering the returns.”

“By including the robot on the cutting table, we make better use of our cutting capacity. So, the robot’s price is not as important because it quickly pays off when our existing cutting table becomes more efficient.

The machine is meant to cut around the clock without needing someone to operate it.

Every unmanned hour we can produce is bottomline profit for us.”

“What difference does the robot make for your employees?”

“For our production team, this translates to reduced strain from static lifting and fewer repetitive tasks often associated with assembly line work. All of this contributes to a more favorable work environment and higher job satisfaction.

We must prioritize the well-being of our production employees since they’re not readily replaceable. Training a new employee to operate our diverse machines can take up to six months, and we greatly depend on their expertise.”

“The aim of automation isn’t to cut down on employees but to ramp up productivity. When robots are introduced, employees shouldn’t worry about losing their jobs; they’ll just be reassigned to different, more engaging tasks.

I’ve never been involved in letting go of an employee because of the introduction of a robot. Quite the opposite! Robots boost efficiency, enabling us to handle many more tasks, which, in turn, fosters additional growth.”

“For our production team, this translates to reduced strain from static lifting and fewer repetitive tasks often associated with assembly line work. All of this contributes to a more favorable work environment and higher job satisfaction.

We must prioritize the well-being of our production employees since they’re not readily replaceable. Training a new employee to operate our diverse machines can take up to six months, and we greatly depend on their expertise.”

“The aim of automation isn’t to cut down on employees but to ramp up productivity. When robots are introduced, employees shouldn’t worry about losing their jobs; they’ll just be reassigned to different, more engaging tasks.

I’ve never been involved in letting go of an employee because of the introduction of a robot. Quite the opposite! Robots boost efficiency, enabling us to handle many more tasks, which, in turn, fosters additional growth.”