In Weert, The Netherlands, the manufacturing in the Philips' plant of special bulbs has been producing for the past 40 years. Last year they produced about 140 million ‘non-standard’ bulbs. The PAR-bulb (Parabolic Aluminized Reflector 38 inch) is manufactured in a production hall with up to 22 kinds of bulbs with different characteristics. They are applicable for outside lighting, traffic lights, underwater lights and shop lightning.

FIFO accumulation system
“It has been almost 10 years since we first installed a FlexLink conveyor system in this plant”, says Lambert Seghers, Manufacturing & Maintenance Engineer. “The centralized engineering department within the Philips Group had already had good experience of FlexLink.” “The handling in this particular manufacturing process is very delicate. Therefore we need automation systems in which the products do not bump”, explains Lambert Seghers. “Moreover, all machines in this plant are running nearly six days a week, 24 hours a day now. A failure is so expensive, that we must do everything to avoid it.”

Pick & place units
A few years ago, the manufacturing department had two pick & place units constructed with FlexLink automation components. One unit automates the supply flow of cups (lower side of the bulb). The second unit handles the supply flow of the lenses (upper side of the bulb). The cups and lenses are presented per nine pieces in plastic trays. Piles of trays are put on a pallet.

First inspection of FlexLink installation in 10 years
A similar manufacturing line will soon be transferred from the US to Weert in Holland. This means that the Dutch factory will run five days a week in two shifts. “At the moment, we are checking all machines in detail, making all necessary repairs and upgrading. This means that the FlexLink installations have been inspected for the first time since the installation ten years ago. A part of the system has already been optimized”, tells Lambert Seghers.

FlexLink – experts in conveyor systems
Lambert Seghers had recently appointed to coordinate the current adjustments. This is his first real experience with FlexLink. “When the FlexLink fitters were doing revisions on the systems, I realized that conveyor systems require skills and knowledge that is at FlexLink, he says."