Bosch Rexroth supports STILL with its ActiveAssist digital assistant

With more than 9 000 employees, 8 production sites and 286 sales outlets worldwide, STILL is a leader in the design and manufacture of forklift trucks, warehouse machines, tow tractors, conveyors and systems for integrated logistics.

The extensive STILL product range includes more than 60 models that meet every requirement, from electric and internal combustion trucks of up to 8 tonnes to manual pallet trucks, including three-way trucks and tow tractors. ?We have a long tradition of innovation?, says Loreno Leri, Marketing Director of STILL Italy. ?Since we launched the EK 2000 electric pallet truck on the market in 1945, STILL has always been a pioneer in innovation, with technologies such as hybrid drive, which has only recently been developed in the automotive sector. It is precisely its commitment to developing innovative, environmentally responsible drive systems that sets STILL apart and has made it its motto: ?Mission Zero Emission’?.

Safety in the production of forklift trucks and warehouse machines: an additional asset

Another area in which STILL is at the forefront is safety. All forklift trucks and warehouse machines are equipped with preventive systems for increased driving safety, such as side restraint bars where there is no cab and sensors on seat belts. The trucks can also be fitted with active systems that interact directly with the machine, such as obstacle detection devices, speed reduction in particular conditions or detection of people in the truck's working area. Passive devices that can be activated by the driver are also available: audible and visual warning devices, cameras and laser pointers that assist in positioning and removing the load, and truck power reduction systems that can be activated by the driver, or weighing systems that prevent handling an excessive load or lifting to dangerous heights.

A partnership with Bosch Rexroth towards Industry 4.0 in the automation of production processes

For many years, STILL has been developing 4.0 solutions ranging from the simple forklift truck with integrated warehouse software, to racking, including the development of customised turnkey projects. It was in this context that STILL's collaboration with Bosch Rexroth began in 2014, to meet the need to completely renew the workstations on a new assembly line. STILL chose Bosch Rexroth in particular to equip its production site in Luzzara, Italy. Among the main reasons for its choice, Bosch Rexroth's ability to offer a very rich package of solutions already in the catalogue and the possibility of reducing the industrialisation time of the production line made the difference.

ActiveAssist Bosch Rexroth: a simple and user-friendly digital assistant to support operators

STILL decided to adopt ActiveAssist: this system, based on freely configurable software, creates a dialogue between the assembly stations and the company's IT network. Combined with sensors, touchscreens, cameras and projectors, this assistance system guides operators precisely through the various stages of production, for example when picking the right material for the type of truck being assembled.

ActiveAssist replaces traditional pick-to-light systems and now offers STILL numerous benefits, notably greater flexibility (variety of components to be assembled), ease of programming and additional functions beyond controlling parts picking, for example control of the manufacturing cycle. ?We are very satisfied with our collaboration with Bosch Rexroth? say Massimo Zucchelli, Industrial Engineering Manager, and Daniele Aleotti, Industrial Engineer, STILL Luzzara. ?We opted for the ActiveAssist digital assistant because it fully meets our need for an intelligent system able to guide the operator, thereby reducing errors and simplifying material management?.