At JO Safety in Lolland-Falster- Denmark, resides the fully automated cutter and robot ”Murphy” – as it is fondly called. Murphy is named after the lead character in the SciFi movie ”Robocop” – and in its own way plays a hero-part in the company.

The story of Murphy goes back to 2017, when JO Safety first came into contact with Zünd Skandinavien regarding an automated cutting system. Thomas Hovmand, CEO of JO Safety met Zünd at Sign, Print & Pack fair, where he shared with them the challenges of their existing production.

At that time, most of their jobs were cut by hand, punched out, or cut on roller cutting-machines.

2017

However, the speed of production could not keep up with the ambitions, which were to expand into the Nordic market. In order for them to scale production, new and better ways had to be found to optimize material and automate production.

Zünd was at this time well underway with robots and was considered by JO Safety to be one of the only serious suppliers for the task.

At JO Safety in Lolland-Falster, Denmark resides the fully automated cutter and robot ”Murphy” – as it is fondly called. Murphy is named after the lead character in the SciFi movie ”Robocop” – and in its own way plays a hero-part in the company.

2017

The story of Murphy goes back to 2017, when JO Safety first came into contact with Zünd Skandinavien about an automated cutting system. Thomas Hovmand, CEO of JO Safety met Zünd at Sign, Print & Pack fair, where he shared with them the challenges of their existing production.

At that time, most of their jobs were cut by hand, punched out, or cut on roller cutting-machines.

However, the speed of production could not keep up with the ambitions, which was to expand into the Nordic market. In order for them to scale production, new and better ways had to be found to optimize material and automate production.

Zünd was at this time well underway with robots and was considered by JO Safety to be one of the only serious suppliers for the task.

Zünd and JO Safety were now in dialogue, and in early 2018 Thomas Hovmand received the first price indication from Zünd. At that time, both manual and automated solutions were discussed.

When Zünd celebrated it’s 20-year anniversary, JO Safety took part in their open-house event, and experienced a Zünd S3-cutter with robot automation. This was very close to what they needed – but with certain additions and adjustments.

2018

JO Safety’s needs were subsequently specified with the following requirements:

  • The system must automatically load sheets into the machine.
  • The system must be able to automatically retrieve cutting-data from individual prints that are in the same stack.
  • The system must be able to cut/mill the plastic plates with a satisfactory result.
  • The system must be able to pick the finished-cut items automatically and dynamically, without manually having to set and programme the robot.
  • The system must be able to sort the picked items into numerous stacks or boxes.

At that time, Zünd did not have a final solution that could meet all JO Safety’s requirements and needs. But the challenge was exciting, and Zünd chose to accept it.

2018

Zünd and JO Safety were now in dialogue, and in early 2018 Thomas Hovmand received the first price indication from Zünd. At that time, both manual and automated solutions were discussed.

When Zünd celebrated it’s 20-year anniversary, JO Safety took part in their open-house event, and experienced a Zünd S3-cutter with robot automation. This was very close to what they needed – but with certain additions and adjustments.

JO Safety’s needs were subsequently specified with the following requirements:

  • The system must automatically load sheets into the machine.
  • The system must be able to automatically retrieve cutting-data from individual prints that are in the same stack.
  • The system must be able to cut/mill the plastic plates with a satisfactory result.
  • The system must be able to pick the finished-cut items automatically and dynamically, without manually having to set and programme the robot.
  • The system must be able to sort the picked items into numerous stacks or boxes.

At that time, Zünd did not have a final solution that could meet all JO Safety’s requirements and needs. But the challenge was exciting, and Zünd chose to accept it.

By April 2019, Zünd was so far in the process that they could provide a realistic price and start developing the solution.

Also at this time, JO Safety was also presented with the first 3D illustrations of the complete solution. The solution itself was created by a team of technicians, engineers, and programmers from Zünd.

2019

An industrial ABB robot with appropriate range and lifting capability was selected.

Between Zünd and JO Safety, it was decided that a safety shield was the best-suited solution for the production area. The picking and sorting functions had to be integrated with the Cut-it software so that the system could recognize the items for sorting.

When it became clear which solution was best for the task, it was meticulously designed in CAD/CAM and presented to JO Safety.

2019

By April 2019, Zünd was so far in the process that they could provide a realistic price and start developing the solution.

Also at this time, JO Safety was also presented with the first 3D illustrations of the complete solution. The solution itself was created by a team of technicians, engineers, and programmers from Zünd.

An industrial ABB robot with appropriate range and lifting capability was selected.

Between Zünd and JO Safety, it was decided that a safety shield was the best-suited solution for the production area. The picking and sorting functions had to be integrated with the Cut-it software so that the system could recognize the items for sorting.

When it became clear which solution was best for the task, it was meticulously designed in CAD/CAM and presented to JO Safety.

FAT Test

The whole system was built at Zünd’s facilities in Odder, giving the freedom to develop and calibrate the system to perfection.

When Zünd themselves were satisfied, JO Safety was invited to a Factory Acceptance Test (FAT), which went according to plan. The system was then dismantled and packed for delivery and installation.

2019 – 2020

Installation

In December 2019, the system was installed in a matter of two weeks, and hereafter immediately put in production.

The design of the system took into account the floor space available in the production facility, and the solution was adapted so that no compromises had to be made.

2019 – 2020

FAT Test

The whole system was built at Zünd’s facilities in Odder, giving the freedom to develop and calibrate the system to perfection.

When Zünd themselves were satisfied, JO Safety was invited to a Factory Acceptance Test (FAT), which went according to plan. The system was then dismantled and packed for delivery and installation.

Installation

In December 2019, the system was installed in a matter of two weeks, and hereafter immediately put in production.

The design of the system took into account the floor space available in the production facility, and the solution was adapted so that no compromises had to be made.

”Without the cutter, it would not have been possible to exploit the business opportunities that in a matter of very short time appeared”

Kim Bekker Rasmussen

Manager of Development and Production

2021

Significant increase in production

JO Safety produces signage for all types of businesses all over the world. They are an approved supplier for i.a. Siemens, which uses vast amounts of signage for their wind turbine production.

They produce signage in plastic, vinyl with kiss-cut, and acrylic. Here, items are sorted manually, as the robot is primarily configured for plastic items.

For plastic signs, they use the robot to pick and sort the items. The whole process is fully automated – from when the sheets are placed on the table until they are fully sorted in the 30 boxes.

Kim Bekker Rasmussen explains:
We can leave a huge stack of plastic items on the loading table, press “autoplay” – and then let Murphy feed, cut, and sort the items automatically without errors. We usually do this at the end of a workday. Then the production is finished and ready for packing the next morning.

There has been a noticeable increase in production since Murphy’s arrival. Items that previously had to be punched out can now be cut. This gives us greater flexibility and faster conversion, as well as increased speed in general.”

Quick adjustment opened up new business opportunities

When the COVID pandemic hit, the need for signposts, distance floor signs, markings for chairs and tables, etc. erupted from one day to the next. The Zünd cutting system made it possible to develop and produce new items in different sizes in a matter of hours.

Kim Bekker Rasmussen says:
“We were so overwhelmed by the number of new jobs, that we literally had to work around the clock, and still we could not keep up! There were lines of vinyl rolls all the way down to the assembly department waiting to be cut.

Without Zünd it would not have been possible to take advantage of the opportunities that emerged in the wake of the pandemic.”

2021

Significant increase in production

JO Safety produces signage for all types of businesses all over the world. They are an approved supplier for i.a. Siemens, which uses vast amounts of signage for their wind turbine production.

They produce signage in plastic, vinyl with kiss-cut, and acrylic. Here, items are sorted manually, as the robot is primarily configured for plastic items.

For plastic signs, they use the robot to pick and sort the items. The whole process is fully automated – from when the sheets are placed on the table until they are fully sorted in the 30 boxes.

Kim Bekker Rasmussen explains:
We can leave a huge stack of plastic items on the loading table, press “autoplay” – and then let Murphy feed, cut, and sort the items automatically without errors. We usually do this at the end of a workday. Then the production is finished and ready for packing the next morning.

There has been a noticeable increase in production since Murphy’s arrival. Items that previously had to be punched out can now be cut. This gives us greater flexibility and faster conversion, as well as increased speed in general.”

Quick adjustment opened up new business opportunities

When the COVID pandemic hit, the need for signposts, distance floor signs, markings for chairs and tables, etc. erupted from one day to the next. The Zünd cutting system made it possible to develop and produce new items in different sizes in a matter of hours.

Kim Bekker Rasmussen says:
“We were so overwhelmed by the number of new jobs, that we literally had to work around the clock, and still we could not keep up! There were lines of vinyl rolls all the way down to the assembly department waiting to be cut.

Without Zünd it would not have been possible to take advantage of the opportunities that emerged in the wake of the pandemic.”

”Without the cutter, it would not have been possible to exploit the business opportunities that in a matter of very short time appeared”

Kim Bekker Rasmussen

Manager of Development and Production

  • JO Safety cuts in vinyl, plastic and acrylic

  • The materials are cut with a Zünd G3 L-3200 with an extension table. The cutting jobs are identified with the Eye in the Sky system which reads a bar code printed on each plate.

  • A Board Feeder feeds the sheets onto the cutting table using suction cups.

  • For sorting, an ABB robot is used for dynamic picking of the cut-out items from the cut-table’s extension table.
  • The robot unloads the individual items into boxes. The items are sorted into 30 boxes on a separate unloading table.

JO Safety primarily prints on plastic, vinyl and acrylic, but is constantly working on expanding its range of materials. The Zünd cutter gives them a unique opportunity to experiment with new materials such as fluorescent plastic and reflective vinyl.

JO Safety is now so busy that they have chosen to extend the working hours for the operators until 8 pm. It’s safe to assume that the cutter is the direct cause for extending the amount of work shifts to keep up with the increased production.

Efficient Collaboration

“If we need sparring, normally someone at Zünd can help us out immediately – otherwise they return quickly to us.

We experience a competent staff with a great openness to cooperation and learning. They are sincerely interested in our experiences and how we solve occasional small problems. For us, range and reliability are especially important in daily operations, but also service and guidance. We think that all things are fulfilled in our collaboration with Zünd.”


Kim Bekker Rasmussen

VISIT JO SAFETY here…