Labadis

Designing a line side delivery

Timothée Prely — Fri, 24 Jun 2022 09:29:57 +0000

Line side delivery, what is it?

Let’s take the analogy of the restaurant: you are at the table, there are plates, bottles, salt, pepper and bread in front of you. You serve yourself regularly at your own pace. The waiter on his side, comes to supply the table at a lower frequency than you’re eating.

Line side delivery is the same thing: the operator “uses” pieces for assembling at his pace and the supplier comes at a lower frequency than that of the turn of keys.

Line side delivery provides the interface between those who produce, the fitters and those who transfer, internal logistics.

Line side delivery integrates the constraints of each other, while letting everyone work at their own pace:

The producer who assembles wants to mover as little as possible and requires the shortest workstation. It imposes compact packaging (bins or trolleys).
The supplier wants to make his trips profitable, and requires a low delivery frequency. It imposes the autonomy of the line side and therefore its depth

Line side delivery is a nomen’s land in a company. It’s an area that is not technical enough to concern production methods and too detailed to concern logistics. And yet it is important because it defines the economic performance of the plant. Therefore, below we have given several tips to integrate in the design of the line edge delivery.

Well-designed packaging

First of all, a container must be defined for each part. This was the subject of a previous article: “how to design good packaging”

See the article

Common ergonomic window

To protect the operator’s backs, we prevent them from bending down. The pieces are placed in the ergonomic window. As the operators change and are different sizes, the common ergonomic window is between 700 mm to 1300 mm. However, we are talking about taking a piece.

As it is the grip of the pieces that must be in the ergonomic window, the large pieces will be placed at the bottom. Therefore their container will be lower and the front capacity of the Rack will be increased.

All under 1 300 mm

In order for the operator to work in good conditions, he must be able to see far and even outside. On the other hand, if he is in difficulty, the workshop management must be able to identify this situation and come to support him. Therefore the edge of the line must be below 1300 mm.

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A single way of supply

It happens that supplies are placed at 90° to each other. This creates empty areas that unnecessarily consume surface and collect miscellaneous objects. By choosing a single way of supply, the surface is optimized and the space clarified. To comply with this rule, there are several types of supply:

Frontal: the pieces arrive perpendicular to the axis of the line
Transversal: large containers or trolleys leave on the other side of the line
Lateral: the parts are taken from the side by the operator, especially at the end of the U-shaped line
Tangential: large pieces scroll along the sides of the line

A return line (All down the drain)

All down the drain is a luxe that no one will be able to live without. Used water returns to the water-treatment plant for a new cycle. This is the same for packaging: as soon as the last piece is taken, next cycle, the operator evacuates the container in a line towards the outside of the line. For trolleys, it will be the same: a line is created for « the empty ». These lines can be put together. We then ensure that they will never be saturated between two passages of internal logistics. For the trolleys, the return for « the empty »will be placed between two corridors of parts to allow lateral transfer by “square step”.

“Limit the impact of frequencies”

The return of empty containers (containers or trolleys) is perceived as a constraint for the operator whose primary action is manufacturing. By putting the return at the bottom, the operator only has to follows the container which slides naturally.

For any input check the output.

Physical guidance

At 70 km/h, the trains cross each other with a spacing of 0.25 m, whereas 1 m is provided for cars. Thanks to the guidance of the rails, we gain 4 times more space between the Rollis. To optimize as much as possible the length of the line delivery, each container, like each trolley, must be physically guided

Taking from above

Some line side units have sloped containers at the end of the row (broken) to allow parts to be picked up. This is due to the use of deep containers with multiple layers of products. This increases the vertical size of the layer by 30%.

By using dynamic racks with taking pieces from above, the space is reduced and the number of supplied parts are increased. The surface and by the operators walk distance are reduced.

One-piece, single-layer containers

If a container has dividers or lids, there must be a dedicated place to put them. This consumes space and furthermore a multi-layered container will require the operator to reach in further to accede the lower levels. With a single-layer container: zero dividers, zero unnecessary gestures, more space for other references.

Small pieces will be placed in butter trays whose small width allows the pieces to be picked up without constraining the hand while having a small frontal surface.

Fixed units

The line side delivery accommodates mobile containers and trolleys. There are always efforts or even shocks during the introduction. So that the suppliers and operators gestures are repetitive, the infrastructures of the line side delivery are fixed, either placed, or screwed. Wheels under the line side units reduce their stability. Any cleaning of these areas is done with a vacuum cleaner and not by moving them.

Straight

The logistics staff who supply the line side delivery do intensive and fast work. To make it easier for them to fill up and avoid them from bumping into each other, all the line side delivery units on the logistics side must be perfectly aligned.

Two roll rule

At a minimum, there is 1 container being consumed and 1 container pending. If logistics have a resupplying of U (10/15/20/30/60 minutes) the line side delivery must have a capacity of 2U + 1 container to avoid any ruptures.

A reconfigurable line edge

Assembling is an activity that often changes due to liftings, new ranges, etc. This has a direct impact on the line side delivery, which will change. Racks and storage modules with a pitch of 450 mm allow this modularity and the investment becomes sustainable.

A gutter for the call signal

The line must inform its supplier, logistics, of what parts they have to deliver. Different ways exist to send a signal to the logistics. For the Kanban system, a gutter will be placed on the line side delivery, to send back the Kanban cards to the Logistics. To avoid the operator losing a card, a gutter will be placed every 2.5m.

The side supply

Des pièces peuvent être plus longues que la largeur de l’allée qui longe le bord de ligne. Il est alors impossible de les mettre en approvisionnement frontal classique. Le système de roues Track & Slide approvisionne les longues pièces en les déplaçant sur le côté depuis l’allée.

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Jean LABADIE

Engineer by training, 40 years in industry, trained by Toyota at TPS, director of industrial performance within the Valeo group, Jean LABADIE created Labadis in 2002 to support manufacturers in all sectors in setting up a simple organization, efficient and sustainable based on the Labadis system.

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Poclain – Kitting trolley

Timothée Prely — Tue, 11 Jan 2022 08:49:34 +0000

Poclain – Kitting trolley - case study

Results

No more supply disruptions
Line edge compactness
Reduced aisles
Improved efficiency

Customer issue

Poclain is an industrial company that manufactures hydraulic radial piston motors for large constructions and agricultural handling equipment. The engine line assembles many references and the parts are delivered at the edge of the line in a 1200 x 800 pallet box. To avoid taking up too much space, only one box per reference is made available. This generates meetings between logistics and operators and therefore they have to wait for one another. In addition, forklifts require a 3.5m aisle.

The parts are all over 15 kg and are handled by hoists.

Labadis Analysis

To answer the customer’s issue / problematic, we had to find a way to bring all the parts in as little space as possible.

We studied the shape of the parts and their assembly sequence to overlap them and maintain access to the hoist gripping equipment.

The analysis showed that the solution had to meet the following constraints:

Accessibility of parts by a hoist
Compactness of the packaging
Parts protection against scratches
Stability

Solution provided

Labadis has designed a 400 mm wide kitting trolley, capable of transporting 120 kg of parts and also stable in a small train.

In order to have only one model of trolley, Labadis studied the bearing faces of all the parts needed to build these different motors and designed a versatile support.

The parts are arranged one above the other and are all accessible by the hoist thanks to hollow supports.

Impacts and scratches on the pieces are avoided thanks to the choice in the design.

Therefore Poclain was able to eliminate waiting times, compact the line edge and reduce the aisles.

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Agriculture and construction machine manufacturer – Tool holder optimisation

Timothée Prely — Tue, 02 Nov 2021 08:43:11 +0000

Agriculture and construction machine manufacturer – Tool holder optimisation - case study

Our customer is an agriculture and construction machine manufacturer who has launched with Labadis a complete production plant transformation. We have led a workshop in order to design an optimized tool holder that improves the gestures to pick up and release the tool, and also to simplify the work station implementation.

Results

Following this workshop and the complete transformation the results are:

Productivity

+ 20%

Surface

– 40%

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

Picture : Labadis Laval tool holder

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

Picture : Labadis Laval tool holder

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.

Picture : Labadis Laval tool holder

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Agriculture and construction machine manufacturer – implementation of a flat storage

Timothée Prely — Fri, 29 Oct 2021 13:22:00 +0000

Agriculture and construction machine manufacturer – implementation of a flat storage - case study

Our customer is an agriculture and construction machine manufacturer that has launched with Labadis a complete production plant transformation. We have led a flat storage work shop to improve the delivery response of the warehouse to the production line request.

Results

Reduction of the line stoppage

Withdraw Kanban system to organize the delivery of parts on the line

Fork lift free and risk-free area in the warehouse piking zone and assembly plant

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

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

Picture: Labadis Laval Flat storage

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

Picture: Labadis Laval Flat storage

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Virax – Redevelopment of the production line

Timothée Prely — Fri, 29 Oct 2021 13:03:42 +0000

Virax – Redevelopment of the production line - case study

Here are the results of a HOSHIN project (Lean manufacturing tools) carried out at VIRAX in order to simply and efficiently optimize the operation of a manual production line.

Results

Labadis intervention on the production line at Virax allowed them to obtain the following results.

+ 40%

Productivity

– 50%

Surface

Customer situation

Virax Epernay design, produce and supply tools for plumbers and hose assembly. The plant has a wide type of process and a high technical expertise. Today Virax wishes to reduce their stocks of outstanding and finished products in order to improve their service rate. To do this, they have to reduce the size of the production batch with the same variety of products.

Labadis diagnostic

On the production line, we have analyzed all steps of a product assembly. For each step, we have observed and measured problems from waste:

Operator produces batch of parts = take, release, take, …
Assembly line is in an L shape, a big space is wasted in the middle
Working stations are at least 3 times wider than the product
Outsourced parts packaging is not compatible with the side line feeding
Vertical shelves increase the grip height
Packaging size increases the movement of the operator and wastes space all along the transfer

Before

Implemented solution

In order to increase Virax productivity, we have worked on 3 steps:

Size reduction for packaging, workstation, tools
One piece flow production and productivity thanks to space removed between workstation
Use of offset Dynamics Rack to compact the station
U shaped line design

After

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How to design a good industrial packaging?

Timothée Prely — Wed, 27 Oct 2021 14:48:34 +0000

You have problems with damaged parts, overpackaged, scratches, missing parts, falls, containers that change with each delivery. They are different but their problems stem from the same origin: packaging!

What is a good industrial packaging?

Here are 9 rules to follow when designing your packaging.

1.Protect

Place all parts inside the packaging, don’t let anything overfill. If your parts are delicate, use separators to keep them apart.

Packaging will protect parts against aggressions such as shocks, scratches and friction…

2.Compact

Choose your packaging according to the shape of the piece, not according to the quantity to be delivered. Package your pieces in the smallest possible container. The small pieces in containers and the large ones in handling Rollis trolley. Your packagings will be more compact and you will be able to position them as close as possible to the workstation or machine.

The quantity is processed through the number of packagings and the frequency of delivery.

3.Simple

Make your pieces directly accessible and place them all in the same way. By avoiding recoveries and reversals, your packaging will be easier to use.

This will increase the productivity of your operators and reduce the risk of shocks.

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4.Obvious

Put a single layer of products per packaging; Avoid high bins with dividers which increase the amount of packaging and clutter up the workstations. Choose a low bin with internal wedges.

5.Stable

Maintain your pieces with only 3 contact points, you will improve their accessibility and avoid packaging waste.

6.Versatile

Packaging for 4 different items

Package your parts in a versatile and standardized way, so the diversity of your packaging will be reduced.

To do this research the common parts of your different pieces such as a bracket, a layer, a hole… You can use the same type of packaging to package different parts.

Such packaging will automate the filling easily.

7.Modular

Choose the 400 mm width to create your packaging. This dimension matches human morphology, it is easier to manage. This dimension maximizes the truck filling rate. For Rollis Trolley type, wherever the human goes the trolley follows.

For container packagings choose a dimension of 400, 300, 200 or 100.

Limit yourself to a minimum width of 100 mm to avoid MSD (musculoskeletal disorders) thanks to a grip without stress for the fingers.

8.Ergonomic

Limit the load of your containers to 15 kg. Otherwise use an ergonomic Rollis trolley or an automatic pile lifter to present your containers in the ergonomic window height. You reduce the risk of injury.

9.Sustainable

With these rules your packaging becomes reusable and sustainable.

Packaging conception needs many decisions which optimization is sometimes complex. Labadis can coach you in the design and realization of your packagings.

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Jean LABADIE

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Press article #6 : tips against the coronavirus at work

Timothée Prely — Tue, 24 Mar 2020 08:20:52 +0000

Our Chinese subsidiary has allowed us to understand day after day how China has adapted to fight covid-19. Before the epidemic arrived in France, we set up a working group to identify risky behaviours, find solutions to implement and then deploy them within the company, applying our organizational techniques.The group has defined physical rules, simple and easy to implement.

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