Modular workstations aid lean manufacturing

Modular workstations assist the introduction of adaptable production cells as part of ongoing lean manufacturing programme.

Switching to modular Lean Tek workstations from Tube and Bracket Company has enabled Emco Wheaton to introduce adaptable production cells as part of its ongoing lean manufacturing programme.

The self-contained production cells can be modified easily and rapidly to support changing manufacturing requirements and priorities and deliver continuous business improvement.

"We are aiming for maximum flexibility in manufacturing methods and what we manufacture so that we can adapt to changes in the market as soon as possible", said Brian Langsdon, Production Controller at Emco Wheaton.

"I wanted something that I could take apart and adapt whenever I wanted".

Emco Wheaton has made products for the safe handling of hazardous fluids for over 50 years and designs and makes petroleum tank truck equipment.

The company, part of Gardner Denver, has recently opened a facility in Margate where it has been based since 1953.

For the past two years, the company has been adopting lean manufacturing to replace its traditional batch and queue production.

The objective is to optimise the overall production process and implement cellular manufacturing and related concepts such as single piece flow, Kanban and 5S to support flexible production processes and continuous business improvement.

When it started its lean manufacturing programme, the company fabricated its own workstations by welding steel components.

These workstations performed well but as the programme developed the company recognised that greater adaptability was required so that production cells could be modified and configured to meet evolving production requirements.

"The key benefit of working with Tube and Bracket is the partnership we have developed", said Langsdon.

"We discuss ideas and they come up with something quickly".

Working to Emco Wheaton's basic specification, Tube and Bracket devised and built ten workstations with modular Lean Tek components.

The range of interchangeable and reusable components includes tubes, brackets, wheels and accessories that can be assembled into lightweight and manoeuvrable workstations, carts and trolleys that provide greater flexibility and cost effectiveness than devices made from welded steel and similar materials.

The workstations were designed to be self-contained for use in production cells for two of Emco Wheaton's core products.

They include areas for product working and assembly and incorporate ancillary facilities for lighting, power and air supply.

Production schedules and other information can be displayed on small noticeboards integrated into the overall design.

Each workstation is mounted on locking wheels and can be moved or repositioned easily by one person.

In line with lean manufacturing thinking, the workstations have been designed to optimise the working environment and occupy exactly the right amount of space for the process they support.

The modular nature of their construction means they can be modified whenever production requirements change by altering the basic dimensions or by the addition or removal of components.

"Tube and Bracket has given us nice clean workstations which include all the accessories for these production cells", said Langsdon.

"It is key to the factory that everything has its place and it becomes obvious when it's wrong".

Tube and Bracket assembled the workstations at its factory in Banbury and delivered them to Margate.

Small modifications were made during installation to ensure that the production cells were optimised for efficiency.

Further changes were made as the production cells went live.

Each workstation originally had two locking wheels but it was soon realised that four would provide better stability.

Tube and Bracket supplied and fitted the additional components on site.

The workstation noticeboards were also repositioned to make them easier to see.

"We couldn't do this with a welded workstation", said Langsdon.

"If a cell is not right, we can take it apart and rebuild it".

The production cells will enhance Emco Wheaton's lean manufacturing capabilities and help it introduce single piece flow for its core products.

As the company continues its drive towards lean manufacturing, it plans to standardise on adaptable modular products for its production cell workstations and other equipment.

"One of the challenges with this type of change is that it's an ongoing process", said Langsdon.

"We wanted to work with a company that understood what we're doing and could help us provide a uniform system throughout the factory".

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