LEAN Automation from Coil: Producing More with Fewer Staff – Opportunity or Necessity?
LEAN Automation from Coil: Producing More with Fewer Staff
In Europe and the USA, we’re witnessing a strong return of local industrial production: a phenomenon known as reshoring, driven by the need to shorten supply chains and improve industrial resilience.
But to remain competitive in the new manufacturing era, we can no longer rely on labor-intensive models.
The future – or rather, the present – is automation: producing more with fewer human resources, focusing on more qualified, motivated, and digital personnel capable of managing complex and efficient systems.
This is how Dallan has made it a reality with its LEAN systems from coil.
🏗️ High-Capacity System for Drywall Profiles: Up to 35,000 meters per day
Dallan lines for thin sheet metal drywall profiles are a perfect example of advanced automation:
Coil unwinding
Roll forming at 120 m/min
Automatic packaging into Masterpacks with wooden slats
Requires only 1 operator
With this system, a single operator can produce up to 35,000 meters of profile per day – the equivalent of 3–4 operators using traditional systems.
🎥 Watch the video:
🏗️ System for T-bars and Suspended Ceilings: Precision and Integrated Quality Control
Dallan lines for T-bar profiles and ceiling structures include:
Production up to 100 m/min
100% in-line quality control on each piece
Automatic packaging into boxes, ready for shipping
This means one Dallan line can match the output of three traditional lines, saving 67% or more in labor while maintaining top quality.
🎥 Watch the video:
🪟 Coil to Window System for Roller Shutters: Finished Curtains at the Output
The Coil to Window system for roller shutters is the ultimate in automation within a single line:
Starts from pre-painted coil
Profiles are formed, cut, assembled, end-capped, and stacked
All automatically, according to a production list
👉 One operator is enough to produce up to 600 m² of finished curtains per day!
Compared to bar production, this saves 75% of labor, while reducing waste and errors.
🎥 Watch the video:
💡 Parametric Programming: Goodbye Manual Programs
One of Dallan’s most powerful innovations is parametric programming:
Machines don’t need a DXF file for every part, only a list of variable parameters like:
Length
Hole number and position
Cut type
Profile dimensions
📌 The result is intelligent, automatic production management – perfect for Just in Time applications.
No time wasted in technical offices, no human error, maximum flexibility!
🎯 Up to 75% Reduction in Operational Staff
All these examples lead to one tangible result:
Less labor required per meter produced, with operators becoming supervisors of smart systems.
Companies that adopted Dallan systems achieved:
Up to 75% labor reduction
Improved safety and job quality
Increased productivity and margins
📩 Ready to reorganize your production?
Contact us and automate your production to be competitive in the future:
📧 [email protected]
We offer our expertise to help you design a custom high-automation LEAN system from coil for your products.
✅ Series Conclusion
With this article, we conclude our journey through the 4 pillars of LEAN Coil Production:
Productivity
Efficiency
Flexibility
Automation
To receive the full series or the book “The Efficiency Revolution”, contact us – we’ll help you build your LEAN factory of the future.