This philosophy is designed to reduce and avoid unnecessary costs, reduce unnecessary inventory, improve the quality of the manufacturing process and the product itself.
The following issues are closely linked to Lean manufacturing:
- elimination of waste,
- Kaizen improvement process,
- products flow in the pull system – shortening the flow time,
- economics of elementary movements in the improvement process, total elimination of unnecessary elementary movements or their simplification,
- elimination of inventory in the production process,
In order to efficiently use the principles of this philosophy, it is necessary to:
- inculcate in employees of all levels the principles that will help to operate in accordance with the principles of Lean manufacturing,
- implement the plant’s organization in accordance with the relevant rules,
- equip the plant with tools enabling the use of the acquired rules in practice.
Although there are numerous theoretical studies, as well as companies providing training in the Lean production theory, there are few companies on our market that are able to offer assistance in the selection of tools appropriate for your company, or to establish cooperation with your specialists to optimize these tools.
We are here to help you. Our company specializes in the design and manufacture of these types of tools. Our employees have the necessary knowledge and experience for creating optimal tools for the efficient operation of the production process. Our products are built using the components of recognized global manufacturers, the main one being Bosch Rexroth. We derive many solutions from the MPS (Manual Production System) product group created by the aforesaid company and successfully used in many factories around the world.
Our solutions are, among others:
We construct our stations with the highest possible use of the principles of ergonomics, which leads to the elimination of excessive movements or to their simplification. Whereas assembly stations additionally equipped with auxiliary tools allow to effectively conduct works pursuant to the 5S philosophy, which translates to fewer losses in manufacture. This results in maintenance of a greater order at the workstation which is conducive to observing and eliminating irregularities i.e. conducting in line with the Kaizen philosophy. If the Kanban system is used at the factory, workstations allow for cooperation with this type of system. See more
By combining individual stations into one process line, and combining them with a logistics system based on supplies of components through the so-called milkman, we are able to built an assembly line which operates in accordance with the principles of Lean manufacturing. Depending on the specificity of manufacture and principles in force at the given factory, the created lines can have a linear structure or be U-shaped. See more
Our company is able to design and execute carriages for a logistic train dedicated to specific needs of even the most demanding Customers. In addition to the sufficient number of spaces for products in various-size containers, we build carriages with specialized holders intended for cast, moulded and pressed pieces, as well as hangers intended for cables, electric harnesses, hoses and drive belts. We can appropriately mark the carriages so that they are easily identified by the personnel.See more
In order to gather the optimal quantity of goods at the workstation, allowing to conduct manufacture without losses, our company offers material carts. The application of carts enables to set up production quickly, thus eliminating the costs of downtimes and set-ups. Material carts are also used when the manufactured element has a considerable size, and placement of all the sub-assemblies at the workstation would conflict with the principles of Lean manufacturing. The carts offered by our company can have shelves in the form of chutes built from various types of materials, as well as sets of roller rails identical to those used in flow racks. See more
Used for gathering, near workstations, of elements necessary for conducting the manufacture process in optimal quantities. These can also be dedicated to storing ready products in order to minimize transport times which cause great losses and do not generate added value. The racks are constructed so as to mount sets of roller rails of the appropriate type and size inside the aluminium support frame. The racks are often marked in accordance with Kanban principles. Due to the fact that the products supplied by our company are manufactured according to individual Customer needs, we are able to undertake the construction of racks which occupy a small floor area in the immediate vicinity of the workstation, while observing the ergonomic principles of loading and collecting goods.See more
The aim of the FIFO principle (first in, first out) is to first use materials supplied the earliest. This principle is applied especially when expiration dates of the stored products are important (food, chemical and pharmaceutical industries) or when it is important to use elements from specific production batches (automotive industry). These stations can be entered by material carts or logistic trains' carriages so as to first use the ones entered the earliest. Our company is experienced in building both small stations holding several carts and stations which organize the flow of materials in the entire storehouse of elements used for production. These stations are most often used in combination with the Kanban system. See more
Elements used for building tools which support operation in accordance with Lean production:
A tubular system created by Bosch Rexroth characterized by tubes made from anodized aluminium. The system uses couplings allowing to join structures executed based on EcoShape with classic structures executed based on a system of aluminium profiles by Bosch Rexroth.See more
a) System of U-type roller rails – characterized by the fact that, as opposed to steel roller rails commonly used by most manufacturers, these are executed as a row of rollers embedded in a dedicated aluminium profile with a process groove located in the bottom part of the profile. Such a solution gives the rails a high load-carrying capacity and rigidity. Our designers often use them in assembly stations where it is necessary to deliver containers with products very close to the operator. If classic steel rails are used, it is necessary to built a frame supporting the ends of the rails. In our case this is not necessary.
b) Movlink gravitational roller transporter tracks – used in the case of very small or heavy elements. Roller rails usually come in several varieties with different diameters and spacings of rollers. These rails are also characterized by a limited load-carrying capacity of tracks. Based on the transport rollers by Movlink, we are able to create transport tracks that could not be achieved using classic roller rails.
c) Driven transporters – in order to increase the efficiency of production lines and to reduce losses, it is sometimes necessary to incorporate into a production line a transporter allowing quick and accurate delivery or pickup of the product. The transporters are also used to enforce pace of the production process. Depending on specific aspects of production, we use belt, roller or pallet transporters. Our transporters are characterized by modular design and reliability. These parameters are very important whenever it is necessary to ensure continuity of production.
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