Customer situation

Our customer produces between 10 and 40 equipment per day. To keep the plant running he needs to improve productivity.

The final product is big, but it’s an assembly of small a middle sized parts that are riveted, screwed etc… with several different types of tools

Analyse Labadis

Cycle time is about 20 to 60 min and seeking for saving seconds is not the current improvement state of mind

Waste :

• Operator has to walk to reach his tools
• It takes time to find the right tool amongst the stack of tools, pick it up and it then let it go
• Every other cycle he grabs the tool in the wrong position and then needs to flip it in his hand into the right position
• Some basic tools are multi-purpose and requires a set up to be operational

Labadis solutions

We have downsized the tool holder to install it closer to the point of use. No flat surface so as soon as the task is done, there is no choice than dropping the tool on its specific holder so always placed in the right position.

A single task tool is a cheaper and more reliable tool than a multi task tool. When needed, we have duplicated the tools to keep them close to the point of use

The tool holder is more than just a stand to place the tool while it is not needed, thanks to this solution, the operator has direct access to the tools which are presented always in the same position, ready to be picked up and used. Grabbing the tool becomes a mechanical reflex for the operator.

Flat surface is a landing area for tools that are dropped even thrown down by the operator eager to start on the next step. Every flat surface has been removed.

1.

Customer situation

• Production lines are often down because of missing parts linked to the delivery lead time from warehouse
• High rack storages require fork lift and specific equipment that are expensive, dangerous and not efficient
• Storage height doesn’t allow a visual management of the stock

2.

Labadis diagnostic

• Warehouse picking lead time is higher than the assembly lines requested lead time. To be able to supply parts on time, warehouse anticipates the request and creates a sub storage on the floor.
• Packaging filling rate is low, even if all locations are occupied, warehouse contains a lot of empty volumes
• Space between two pallet racks is twice the width of the pallet rack itself
• Repacking is done all along the production flow with small quantities

3.

Labadis solution

• Direct access to all parts from the ground without any lifting device = flat storage
• Use the same packaging to feed the line and stock in the warehouse
• Repack all parts in the correct packaging before storing them
• Depending on the quantity to stock, create 3 to 4 areas designed in terms of storage type (gravity racks, trolleys) and length