Assembly at record speed: Study confirms time savings of up to 75 per cent with RiLineX

The hardware, software and automation specialist Rittal commissioned an independent study with Fraunhofer Institute for Material Flow and Logistics IML to determine the time saved while assembling its new RiLineX busbar system platform. The result: RiLineX can be installed up to 75 per cent faster than the previous RiLine60 product. The manufacturer’s previous details, which had conservatively estimated a time advantage of around 50 per cent, have thus been greatly exceeded. In some cases, huge time savings have also been achieved in assembling devices. The study was carried out under real working conditions at the medium-sized switchgear manufacturer gefeba Elektro GmbH in Gladbeck, supervised by the renowned German institute.

Assembly rethought

The new RiLineX busbar system platform from Rittal, examined in the study, fundamentally rethinks the electromechanics of 60-mm busbars. An innovative “Click & Work” principle enables quick and tool-free assembly. Moreover, unlike conventional systems, there is no need to design and position holders or to cut parts such as the contact hazard protection.

RiLineX is available either as a pre-assembled complete board, including copper bars for direct installation in the enclosure, or as a bar-less modular system. With the modular process, users now assemble their own highly customised system from modular components. Standard flat rails made of copper, aluminium or Cuponal in a variety of cross-sections, which are available worldwide, only need to be cut to length or size and then easily inserted. 

The highlights of the study

To independently validate the speed advantages of RiLineX during assembly, inherent in the system design, the assembly procedures for RiLineX complete boards and modular systems using the so-called REFA standard procedure were compared with those for the predecessor RiLine60 system, which is widely used in the industry. The study also differentiates between a manual assembly process and the use of CNC-supported drilling. Assembly work was carried out by experienced specialists from the Gladbeck-based gefeba switchgear manufacturer.

The greatest time benefit was achieved when using the prefabricated RiLineX complete boards: Compared to the RiLine60, assembly time was cut by 75 per cent with manual processing and 80 per cent with CNC support for drilling. However, the RiLineX modular system also showed a clear time saving of 60 per cent during manual assembly and 55 per cent during automated assembly. With the modular board, the time saved with CNC drilling is somewhat less than with manual drilling, because (unlike with the compact board) the machine needs to be used several times, and the board has to be processed with different drilling plans. The time savings when attaching device components depend on the type and can be as high as 85 per cent.

“The significantly faster assembly time with RiLineX really surprised me,” Marcel Birkenberger, Head of Manufacturing and Production at gefeba Elektro GmbH, points out. “The first impression of RiLineX was already positive when Rittal presented the product. The system seemed well-conceived and uncomplicated. But we couldn’t imagine how big the actual time advantage would be in practice.” In the future, gefeba intends to exploit this advantage. “Since its founding, a strong customer focus has driven our family business. If we want to keep things that way, we will need to keep an eye open for innovations to enable us to meet the ever-increasing demand for short delivery times, even for complex solutions.” Volker Schmidt, Head of Product Management RiLineX at Rittal, adds: “For the relevance of the study, it was important that we selected a company with fully qualified professionals and with extensive experience in the efficient use of the busbar systems currently available on the market, such as RiLine60. Everything worked out right at gefeba.”