Tobol optimized its control cabinet production together with Phoenix Contact

Using lean methods, Tobol transformed its production from job-shop to flow-oriented, resulting in faster, more efficient output with minimal errors.

Black lines structure Tobol GmbH’s new switchgear facility in Leinefelde, Thuringia, where workers follow clear production steps in a clean, organized space. Alongside building the hall, Tobol restructured its switchgear operations using material flow and value stream principles. Consultant Henning Rey guided the lean transition, which General Manager Tobias Funke says greatly improved speed and efficiency.

Future-proofing its production

Since 1997, Tobol has provided custom MCR automation solutions for data centers and buildings, with a strong focus on HVAC, energy, and monitoring. Eighty specialists plan and design top-tier systems for clients across Europe, while the team produces premium switchgears in Leinefelde. As demand rises and skilled labor becomes scarce, efficient switchgear production remains critical to maintaining competitiveness, says Plant Manager Ralf Krause.

The new hall in Leinefelde allowed Tobol to rethink switchgear production. Aligned with its All Electric Society strategy, Phoenix Contact aims to streamline these processes. “In 2018, we decided to optimize product handling in control cabinet building,” says Bernd Naguschewski. Their early consulting helped integrate material flow and value stream principles into the layout.

Metal processing starts the production chain to keep chips out of the assembly area. Design engineers oversee the hall from their offices above, sending circuit diagrams, bills of materials, and layouts to production and logistics, where orders are picked. Thanks to optimization, Tobol now has a dedicated logistics area. This saved skilled workers time otherwise spent searching for materials, noted Henning Rey.

Process based on partnership

Consultants like Henning Rey often face skepticism toward efficiency and digitalization, mainly due to resistance to lean methods in traditional production. Tobol is now well-equipped for such changes: “We can now handle orders we couldn’t before, including series orders,” says General Manager Tobias Funke.

However, change takes time. “First, we invited Tobol employees to Blomberg for an objectives workshop,” says Bernd Naguschewski. Phoenix Contact now involves staff early in production planning to improve acceptance and efficiency, unlike before. One example is cardboard engineering, where employees first prototype workstation designs using cardboard models.

Engaging employees with cardboard engineering

Before starting, a detailed workflow analysis is recommended to clarify employee needs, walking distances, and necessary tools, says Henning Rey. Using cardboard models, workflows can be simulated and systems analyzed without the cost of real equipment.

Production employee Frank Klaus and his team poured their energy into the project, repeatedly adjusting the shelf and refining the setup until it worked. Previously, long walking distances across the hall were a constant issue.

The workshops led to more than just new trolleys, walkways, and a tidy hall. Materials are now delivered just-in-time, production status is digitally displayed, and all updates are logged in the system. Tobol finds morning shop floor meetings especially effective.

Improving every day

Each day at 9:46 a.m., Tobol employees gather for a 10-minute meeting led by a rotating presenter, today Plant Manager Ralf Krause. These sessions streamline communication, resolving issues early and efficiently.

Errors are logged directly into the system, giving Krause constant oversight: “Digitalization brings transparency and timely feedback.” General Manager Tobias Funke credits Phoenix Contact’s consulting for leaner, faster processes. Employee satisfaction has also grown, with Frank Klaus noting, “Designing our own workstations in the new facility is a dream come true.”

Advantages of digitalization and integration of assistance systems

Use up-to-date data with change tracking
Clearly represent complex processes
Efficiently handle custom one-off production
Deploy semi-skilled workers in roles once limited to skilled staff
Improve quality by detecting and preventing errors during production

Learn more about control cabinet building.