Control cabinet building efficiency has become a key priority for manufacturers. Rising demand, shorter delivery times, and increasing complexity put pressure on production teams. As a result, companies need production environments that are both flexible and efficient.

To address this challenge, Phoenix Contact and PGA partnered to modernize control cabinet manufacturing. Their project focused on two areas: factory planning and workstation design. Together, these improvements increased quality, reduced production times, and enhanced ergonomics.

Phase 1: Smarter factory planning

The project started with a detailed 3D production layout. This layout created the foundation for a structured and future-ready factory. Moreover, it allowed teams to organize work areas around actual production needs.

A major improvement involved separating key process steps. Teams could then complete tasks in parallel and prepare work more effectively. As a result, production became faster and more flexible.

Material flow was another major focus. Phoenix Contact consultants worked with PGA employees to analyze internal routes and identify unnecessary movement. This helped the team rearrange storage, transport, and work areas more efficiently. Marian Juraskovic, a technician and team lead at PGA, noted that the team had not realized how much distance they covered each day until the workshop made it visible.

The planning also balanced workstation and storage capacity. For example, pallet storage spaces were matched to wiring workstations. This helps prevent bottlenecks, reduces waiting times, and supports a smoother production flow.

Phase 2: Modular workstation design

The second phase focused on workstation design. Phoenix Contact experts worked directly with employees to develop concepts tailored to PGA’s requirements. A key element was a pipe clamp system, selected for fast installation, flexibility, and cost efficiency. The system allows individual, process-oriented workstations to be configured quickly and adapted when requirements change.

One practical example is the wiring trolley for manual wiring. It keeps tools, bulk goods, and frequently used wires standardized and within easy reach. This reduces setup time, avoids long searches, and supports efficient, uninterrupted work. The trolley’s clear structure also improves process reliability and accuracy.

Another example is the project trolley, a mobile order-picking trolley tailored to customer-specific project requirements. Materials and components can be prepared by project and moved directly to the workstation, reducing internal transport routes and supporting a smoother production line.

A third improvement is the workstation for preassembled terminal block assembly on DIN rails according to DIN EN 60715. Frequently used terminal blocks and components are available directly at the workstation, eliminating separate order picking. A worker assistance system from Phoenix Contact, combined with pick-by-light guidance, supports intuitive assembly, reduces errors, speeds up work, and enables targeted use of semi-skilled workers.

The project shows how control cabinet building efficiency can be improved through holistic planning, optimized material flows, decoupled processes, and modular workstation design. By combining digital factory planning with flexible workplace systems, Phoenix Contact and PGA created a modern production environment designed for future requirements and employee needs.

Ready to Optimize Your Control Cabinet Production?

The success of the collaboration between Phoenix Contact and PGA demonstrates how intelligent factory planning, optimized material flows, and ergonomic workstation design can significantly improve efficiency, flexibility, and production quality in control cabinet manufacturing.

If you’re looking to streamline your production processes, reduce lead times, and create a future-ready manufacturing environment, explore how Phoenix Contact’s control cabinet building solutions can support your transformation journey.

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For personalized advice on improving your production environment, contact your local Phoenix Contact representative and start building a smarter, more efficient operation today.