Workers on the assembly line can now call for parts without leaving their stations 53 www.drivesncontrols.com July/August 2023 Unit 3B, Lythalls Lane Industrial Estate, Lythalls Lane, Coventry CV6 6FL UNITED KINGDOM T. +44 2476 30 7722 | E. sales@andantex.co.uk www.andantex.co.uk the line to request parts. The main aims of the new system were that: n line operators should be able to call for parts without leaving their station, and with minimal interruption; n tow motors should only be in the milk run when they were delivering parts or returning with empty crates; n the floor space around each station should be used efficiently. It is not practical to hold stock of some large parts, such as seats, for more than a few Takt cycles. These stations require constant replenishment, while other stations need replenishment less often; and n it should generate and capture data. Station operators now call for parts when they have one set left. To do this, they press a button which is connected wirelessly to a “bus stop” – new area next to the supermarket where drivers wait with their tow motors. The order appears on an HMI screen at the bus stop, showing the station and the parts it needs. The next driver in the queue accepts the order, which also informs the station that parts are being delivered. The driver collects the parts and delivers them. At the station, the driver clears the order by pressing a button and takes the empty crate back to be re-stocked. They then return to the end of the driver queue at the bus stop. The times when the operator calls for parts, when the order is acknowledged, and when it is delivered, are all recorded for later analysis. The station delivery works on its own Takt time, which is normally the same as the assembly line, but can be shorter. By reducing the delivery Takt time without changing the production Takt time, a stress test can be performed on the delivery system without affecting production. The results of the reduction in delivery Takt times identifies those stations that would be vulnerable to delivery failures. Remedial action can then be taken before a reduction in the production Takt time occurs. Among the benefits of the new system are that: n production delays caused by waiting for parts have been eliminated; n production has increased; n fewer drivers are needed; n floor space has been saved and re-used for the bus stop; n the whole replenishment procedure is now more flexible, and stations can be easily included or excluded from the system; and n quantifiable data is generated for analysis and future comparisons. n
RkJQdWJsaXNoZXIy MjQ0NzM=