part presentation manufacturing

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Lean manufacturing in metal fabrication: how are your parts presented, this question shouldn’t be overlooked.

• By Jeff Sipes
• January 9, 2018

Figure 1 Presenting parts so that welders do not have to work in awkward positions and giving them room to move about a cell and move parts help to sustain productivity in a job shop.

Piece parts, components, and work-in-process (WIP) are the lifeblood of a manufacturing plant. Without these, we would have no finished goods to sell. And without finished goods, we have no revenue!

We often focus on managing finished goods or warehoused items. (Are procured items in stock? Will finished products be ready for the delivery truck?) As important as these are, I want to shed light on material that does not get the same level of attention: WIP, and more specifically, how WIP is presented to assemblers, welders, press brake operators, and those at other work centers.

Paying greater attention to WIP at this stage of production can have big implications for overall operational performance. The way parts are presented will affect employees’ productivity, product quality, and part flow velocity—that is, how quickly jobs progress through the plant.

Presentation Problems

At its worst, part presentation can be a very loose process. Everybody does it their own way. The material handler wants to drop the material and run. The operator or assembler wants the material close and accessible. The quality control person wants the material stacked in such a way so that he can easily pull out a sample. The supervisor just wants the material completed and moved to the next station. Does this sound familiar?

Let’s imagine a high-mix, low-volume custom fabrication job shop that specializes in complex parts. Consider how flat plasma-cut parts are presented to the fabrication department, where forming, drilling, and welding occur. The finished product has pieces cut from five different thicknesses and grades of steel.

The plasma table and the downstream fabrication operations are separated by some distance. Some parts just cut by the plasma go several hundred feet to a different part of the plant; others go several miles to another facility the fabricator owns across town. Either way, there is a physical break in the process.

The plasma cuts all the parts needed of a given thickness and grade at one time. Operators place cut parts on skids for further processing, including grinding, slag removal, and inspection. The plasma then cuts the next thickness and grade, and the entire process repeats until all five material thicknesses are cut.

To prepare the pieces for the next stage of production, workers must combine all the cut parts onto as few skids as possible so they can move the WIP in as few trips as possible. Remember, the fabrication department (again, where drilling, forming, and welding take place) is far away from the burn table. To reduce the number of skids, material handlers need to mix different gauges and grades together. Workers then transport the skids to fabrication.

Stacking parts on skids becomes a free-for-all with no organization, and the parts show up in fabrication in one big lumpy, mixed collection. So what is the first thing that needs to be done before any value-added work can begin? You got it: People must sort and present the parts to machine operators and welders.

Sure, this parts handling arrangement makes things easy for material handlers, who don’t have to think about where to stack parts, and for the truck drivers, who can move jobs downstream in just a few trips. But their process is disconnected from the fabrication department. Put another way, it is optimized functionally (the function in this case being transportation) but suboptimized for the whole operation, because of the amount of non-value-added sorting and handling in the fabrication department. This takes skilled people away from value-added operations. There is lots of room for improvement here.

Now consider another example about part presentation in a welding cell. Parts need to go from the incoming skid to the weld tacking and assembly fixture, then on to final welding and an outgoing skid.

Although the parts and assembly are lightweight, they are long, awkward, and manually lifted. The welder bends down to take parts off the incoming skid and reaches up and over the fixture to position the pieces for welding. The higher up and farther out he reaches, the greater the strain on his body. Such strain means that the welder has a greater chance of not only mislocating parts in his weld fixtures, but also incurring some significant muscle injuries.

A steady stream of these products flow through the weld cell all day long, and such poor parts presentation can affect the welder’s output dramatically, both in terms of quality and quantity. Productivity becomes an issue because when the welder isn’t laying a weld bead, he is not adding value.

The presentation and handling of materials may have a dramatic impact on the welder’s output. A lost unit of production here, a defective unit there, and time spent stepping away from the weld station result in lost capacity. For a constrained operation, this is a big deal!

Internal Customer Needs and Ergonomics

These two hypothetical situations show what can happen when parts presentation and handling aren’t a focus for improvement. Most likely, other measures and results (did the finished product ship on time?) overshadowed the details of parts presentation and handling.

So how could these situations be improved? First, consider the needs of the internal customer and internal supplier. What can the internal suppliers (those sending parts downstream) do in their processes that will make the jobs of internal customers (those receiving parts) easier, safer, and more productive?

Also pay attention to ergonomics (see Figure 1 ). People should not have to bend or contort them00selves excessively to handle incoming or outgoing work. Dedicate and mark spaces for incoming and outgoing products at the workcell. Position skids, tubs, or other conveyance devices so that the operator does not have to climb over, go around, or otherwise reach, stretch, bend, or contort. Also pay attention to the height of fixtures and work surfaces. Consider adjustable-height fixtures and tables so that operators, welders, and assemblers can work in comfort.

Minimize the number of times operators need to flip or otherwise reorient parts, especially when fabricating large or heavy workpieces. Consider the entire sequence of the operation. Could a process step be eliminated? Fewer flips mean fewer opportunities for errors and accidents.

Also, use lifting devices to minimize worker strain, especially when dealing with large, heavy, or awkward parts. Be creative with the variety of options commercially available, or perhaps build a device that is custom-fit to the operation and product. If you see employees lifting items using poor ergonomic practices, then a jib crane, hoist, or an alternative lifting mechanism may be well worth the investment.

A Better Approach

What would that weld cell look like with better part presentation? For starters, you would see the intersection of 5S, visual control, and flow … all ingredients in the lean body of knowledge.

Open space allows the welder to navigate safely within the cell. Material handlers place incoming work in designated locations. Welders and material handlers move parts from step to step without stress or strain. The weld tables and fixtures position parts so that the welder does not have unnecessary movement and can easily access all areas that need welding.

In turn, the supervisor can be confident that the work is being done safely and effectively. The welder is less fatigued, and there is a steady rhythm through the workcell. When parts go missing or containers are full, it is obvious. In short, the weld cell is much more effective than before.

How about the part flow between plasma cutting and the fabrication department? If people considered the internal customer, the flow would look a lot different. Material handlers in the cutting department would group parts on the skids by job and assembly. Sure, drivers may need to make a few extra trips delivering all the skids, but people in the fabrication department would no longer spend valuable time hunting for the parts they need.

Small Details, Big Impact

Parts presentation is not a panacea or silver bullet, but it is an area ripe for improvement. These small improvements at a detailed level can lead to a more productive and safer workplace.

My challenge to you is this: Go to gemba . Observe some workstations and see how work arrives and departs from the area. Put yourself in the shoes of the person doing the work. Is there room for improvement to make it a win for the employee, the company, and the customer?

Jeff Sipes is principal of Back2Basics LLC, 317-439-7960, www.back2basics-lean.com. If you have improvement ideas you’d like to read about, contact him at [email protected] or Senior Editor Tim Heston at [email protected].

About the Author

Back2Basics LLC

9250 Eagle Meadow Dr.

Indianapolis, IN 46234

(317) 439-7960

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DYNAMIC IMPROVEMENT GROUP

• Jun 21, 2021

Effective Part Presentation to the Operators

Updated: Jul 28, 2021

If most of our money is in our material, then why is it the last thing we engineer at the cell?

A lean manufacturing flow must have an effective part presentation to the operator.

We know the operator Value Added operation is the priority, but when it comes to material, we often do not know how to translate that into a competitive strategy.

If the operator must count, repackage, move, or process used boxes, then we have not done our job as lean engineers. We have the endless task of taking all of those non cyclicals away from the honorable production operator. Give it all to someone else and watch your throughput increase significantly.

Nothing is more personal to our colleagues than material flow on the shop floor. They all know and understand it is wrong to have any production downtime because they have run out of material or because they are waiting for a fork truck for on service demand.

It really annoys me to see operators leave the sanctity of their cells to walk over to a pallet of material and replenish themselves. At the same time, I can show you a fork truck driver somewhere with empty forks.

The concept of Primary Part Presentation and Secondary Part Presentation

You should always engineer flow to the operator so that he or she never stops. You must have zero tolerance on this issue. Primary and secondary means that they always load or unload from a primary location and have a secondary for backup nearby. In today’s competitive world, this means turntables and flow racks for totes. Sometimes it's even more creative than that. Challenge yourself and keep asking the operator if it is working for them.

Just because you have downtime on your lines, it should never be used to have your operators restock themselves, ever. If you subscribe to this methodology, then you need some good lean coaching.

Use your fork-truck driver or tugger driver to “service” the manufacturing cell. That means they need to get off their truck and take away empties, bring full containers, and process all waste in the cell. They might even have to do some recycling along the way.

Take a good look at your cells and see where the operators are placing their parts to load. This means they are talking to you. You may not know it, but they most definitely are.

Also start to look at putting parts into, but out of the way of the operator walk pattern. This alone can save them a bunch of time per cycle.

Part Presentation as an Art Form

A good place to start is with totes on a flow rack. Give them 2-4 hours of stock and do not forget the return lane for empties at the top or bottom of the rack design.

Pipe rails are a creative method if it is supporting the cell from outside to the inside. Do not clog up my walk pattern for the operator please.

4-6” PVC pipe can be elbowed into position for clips, studs, or nuts if the operator needs them. Remember – from outside in.

Flow material through the fencing to the operator closest to the point of use. If you get a safety buy-off, then do not let me get in your way………….

Standard Work in Process. Sometimes you may need some parts in between. Just because you put the last part on the pipe rail inside your line, does not mean you cannot take one from the other side on the other end to load into the next machine.

Part presentation within the operator walk pattern is better than inside the tooling fixture or from the side. Sometimes the operator needs to pick it up and orient it properly for a good load. Remember to feed material from the outside and place the operators on the inside. You do not want a material handler to break the operator’s rhythm and routine.

Off the top of your head – which of your cells needs help with part presentation?

Why do you as a leader live with this when you know that there is a solution?

How much time do your operators spend on material handling?

Do you have operator stack charts completed for each station with VA and NVA designations and percentages?

We at Dynamic Improvement Group are part presentation experts, and we would like to help you with yours…

• Lean Manufacturing

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The Intricacies of Part Presentation in Automating Manufacturing Assembly

October 2, 2023

In the ever-evolving world of manufacturing, automation has played a pivotal role in boosting productivity, reducing costs, and enhancing product quality. One critical aspect of automation in manufacturing assembly is part presentation. Precise positioning and orientation of components for assembly processes can ultimately drive key success criteria for any automation solution, including cycle time, human support and reliability. While automating manufacturing assembly has the potential to revolutionize the industry, part presentation strategies have the potential to up-end the business case for any automation project. In this blog post, we will delve into complexities and obstacles that manufacturers face in automating part presentation and how to address them.

Component Variation and Complexity

One of the primary challenges in automating part presentation is handling inherent variation and complexity of components. Manufacturing companies often produce parts with slight differences in size, shape, and orientation. These small deviations from one part to the next or batch to another can make it challenging for automated systems to identify and handle these components reliably. These variations can result from minor design changes but most often occur due to specified tolerances, material properties, differences in manufacturing environments, or component manufacturing processes.

Possible solutions include implementing advanced vision systems and sensors that can aid in detecting part variations and adapting the automated assembly process accordingly. In practice this means enabling robotics to see and feel parts and then intelligently respond to maintain high yield requirements. Machine learning algorithms can train robotic systems to recognize and handle different component variations effectively.

Orientation and Positioning

Achieving the correct orientation and positioning of components is crucial for successful assembly and meeting fast cycle time requirements. Human workers can quickly adjust part orientation by hand. Replicating human-level dexterity in robots is a complex task. Ensuring that components are presented consistently, in the same location and orientation to assembly robots is a significant challenge that often requires expensive mechanical customization.

Utilizing robotic end-effectors with advanced gripping technologies, such as adaptive grippers and force-torque sensors, can enhance the ability of robots to adjust part orientation during assembly or at least recognize when an error has occurred. This often requires sophisticated software, such as machine learning solutions that enable the robot to respond in real-time with adjustments.

Feeding Mechanisms

Automated assembly lines rely on efficient feeding mechanisms to present parts to robots in a controlled manner. Traditional bowl feeders   vibrate batches of components together to randomize and reorient components, eventually filtering out those that don’t meet the specified orientation. Feeders might not always be suitable for delicate parts that can be easily damaged or irregularly shaped components, such as springs that tend to clump together. Thus part nature can lead to jams in the feeder, misplacements, damaged components and assembly errors.

Designing custom feeding solutions tailored to the specific needs of the components can deliver improved part presentation. Also, consideration for feeding constraints during product design can result in choosing  parts better equipped for standard feeders. Vibratory feeders can be combined with intelligent control systems to reduce the impact on components and enable a wide range of effective part feeding options.

Tolerance for Error

Automated assembly processes often require stringent tolerances to maintain product quality and reliability. Even minor errors in part presentation can lead to faulty assemblies, affecting product performance and safety.

Implementing closed-loop control systems that continuously monitor and correct part orientation during assembly can help achieve higher accuracy and reduce errors. Additionally, employing redundant sensing and feedback mechanisms can further enhance the reliability of the assembly process.

Integration with Existing Systems

Manufacturers often seek to automate part presentation in the area of an existing assembly line to minimize cost and complexities associated with kitting components. Integrating automated part presentation systems into existing infrastructure layouts can be challenging, especially with limited space or complex workflows in a high-mix manufacturing environment.

Conducting thorough simulations and feasibility studies prior to implementation can identify potential integration issues and allow for better planning and modifications. Off-line kitting can reduce the space requirements on the line while enabling greater flexibility and reliability. Collaborative robots (cobots) are often more adaptable to existing assembly lines due to their smaller footprint and ability to work safely alongside human workers.

One of the greatest challenges to cost-effectively automating manufacturing assembly is part presentation, especially in high-mix manufacturing environments where component variation is diverse and critical. Manufacturers need to consider cutting-edge technologies, such as advanced vision systems, machine learning algorithms, and collaborative robots, to overcome these challenges and ensure seamless and accurate assembly processes. At Launchpad, we deliver more cost-effective and flexible part presentation solutions using these more advanced systems proven in other markets. Addressing these challenges head-on enables our customers to unlock the full potential for automation, even in high-mix manufacturing environments.

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Worksmart Systems

Lean manufacturing and assembly, who we are: worksmart systems lean manufacturing experts.

Since 1988, Worksmart Systems has striven to provide innovative and cost effective cells for lean manufacturing and assembly. With products from medical to defense, electronics, transportation, consumer products and everything between, we have extensive track record in creating simple, cost effective solutions. Our areas of experience and expertise include assembly flow, lean manufacturing, ergonomics, parts handling, fixtures, parts presentation, shadow boards, packing, test, inspection, ESD control, error proofing and systems integration. To get an overview of our products please view the video on the right.

What We Do: Worksmart Systems Lean Assembly Cells and Ergonomic Workstations

Worksmart System has 1000's of successful Lean Assembly cells and Ergonomic Workstations installations. The modularity of our system encourages experimentation and continuous improvement. The following videos cover our best practice methods for design of Lean Assembly Cells and Ergonomic Assembly Workstations. An additional video covers 6 Steps for Value Stream Mapping the Assembly Process.

10 Rules For Successful Lean Assembly Cell Design

After designing and building proven and successful assembly and lean manufacturing cells for over three decades, we have put together the commonsense rules that run through our cell concepts. Whether you are building a few or hundreds of units per shift, they will provide benefit, and pay dividends.

5 Steps for Ergonomic Workstation Design

Best practices require sitting or standing height workstations tailored to the operators and task to avoid injury and increase efficiency.

6 Steps to Value Stream Map an Assembly Process

A good approach toward creating a Lean Assembly Cell is to Value Stream map the process.

In this video, Worksmart Systems lays out the course.

How We Do It: Worksmart Systems Case Study Videos

Worksmart Systems doesn't just talk Lean Manufacturing, we help your team create a Lean Assembly Cell or Ergonomic Workstations to your specifications. Additionally we can provide systems integration to enhance the cell’s operation.

Please take a look at some of our installations depicted in the Case Study videos.

Synchronous Flow Lean Assembly Cell

An eight position cell with powered synchronous low and height adjustable, ESD workstations

1. Fleximate Transport Line - Straight ESD Cell with Single Unit Flow, and on Line Test

This 100 foot long cell is an example of a straight ESD cell with single unit flow and on line test for a high volume electro-mechanical product. Other features include custom fixtures, a powered empty cart return, lift and lowering elevators at each end of the cell and mobile parts flowracks.

2. Fleximate Transport Line - Custom pallet cell for a 350# product with a 30" x 39" foot print. 11 Positions in a 100 foot long line

This cell features single piece production with improved ergonomics, supermarket parts presentation, tool handling, on line test and many other enhancements. Other options include, height adjustability, fixturing, error proofing, elevators and automated empty pallet return.

3. Fleximate Transport Line - Oval Configuration with Custom Trunion Fixture

This cell produces a heavy mechanical product. Our fixturing provided manipulation and rotation in two planes which combined with a optimized track height provided efficient worker ergonomics and simple product transfer.

4. Fleximate Transport Line - "S" Configured Cells in a Clean Room Environment

Two long cells for a 250# product. The unique cart design enabled operators to on line inspect for QC. Production flow was a combination of free and powered conveyance.

5. Fleximate Transport Line - Lean Assembly Cell Straight Line

Two custom Fleximate cells featuring unique overhead return of empty pallets due to unique fixturing. Cart tops featured rotation for this high volume automotive application.

6. Fleximate Transport Line - Clean Room Oval Configured Cell with In Line Oven Integration

This application includes a progressive flow through a low temperature oven in a clean room. Also featured is a post cure powered, section for cool down, Custom workstations were integrated into the line to minimize handling of the heavy product and fixture.

7. Fleximate Transport Line - Oval Cell Configuration with Unique Fixturing

This complex mechanical assembly required some fresh thinking for multi access assembly. Custom work surfaces assisted in worker ergonomics and assembly productivity.

8. Fleximate Transport Line - Oval Configuration for a Heavy Product with unique Parts Kitting Capability

This cell featured a re-manufactured product which required that all reused components remain together. We provided a means of keeping the family of parts together with the product housing.

9. Fleximate Transport Line - Mixed Model Cell in Straight Configuration with Supermarket Parts Presentation

On line supermarket parts presentation supporting a high volume, high mix production schedule.

10. Fleximate Pallet Slide Lines - Twin Parallel Straight Cells for a 400# Product

Two sliding pallet cells featuring custom tool presentation, poke yoke, universal fixturing details, and custom power, signal and air distribution. Automated pallet return with elevators and ESD control were other design criteria.

11. Fleximate Transport Line - Mixed Model, Single Piece Flow in a Straight Line

In this application, fixturing and parts presentation was created to produce completely different products. Sub assembly stations produced at point of use with quick change over capability to support mixed model flow. An overhead lift with a lifting yoke made packaging a safe, single operator operation.

12. Fleximate Pallet Slide Line - Short Takt Time, Mixed Model Production in a Straight Line

This cell was designed to handle a wide range of product sizes by incorporating some unique controls and varied parts presentation.

13. Fleximate Pallet Slide Line - Low Effort Sllde Line for a Mechanical Product Family weighing up to 900#

A low volume product that was transitioned from batch to progressive assembly. Unique challenges included height adjustability, multi product, quick change, adapter plates and inline leak testing.

14. Fleximate Transport Line - "L" Configured Cell with Integrated Ergonomic Product Manipulator

Electro mechanical assembly cell with fixturing challenges. Also included was a product tilt assist that transitioned the process from an unsafe, two operator lift to a semi automated, single operator, ergonomic operation.

15. Fleximate Transport Line - High Torque Production in a Straight Line with A Turnstyle feeding Two Test Bays

This cell successfully transitioned a high mix, low volume production from batch to single piece, progressive production. The design wish list included the ability to handle high torque assembly, dual test bays with out production constrictions and an anti-tip safety feature.

16. Fleximate Transport Line - Straight Cell Incorporating Ergonomic Fixturing to assist Assembly

An in depth assembly examination yielded some beneficial fixture considerations. An end of cell, lifting arrangement made packaging a safe, single operator process.

17. Fleximate Transport Line - Straight Cell with Mechanical Assist Product Manipulation

This mature product was transitioning to a single piece flow with standard work procedures. We incorporated ergonomic fixtures and a high pressure test process in line and yielded high productivity.

18. Fleximate Slide Line - Transition from Batch Production for a Heavy Product Family. Cruciform Layout

This cell featured a stainless steel fixture plate rolling on custom roller tracks with multiple safety features for up to a 1200# product. The high mix, low volume product line required height adjustability, low effort, production flow, and multiple test bays. A powered turntable allowed production to flow, uninterrupted, into one of three test positions.

19. Fleximate Transport Line - A "U" configured Cell with Stringent ESD Control Requirements

Multiple work height stations, high performance ESD control and integration of a UV cure tunnel were just a few of the requirements for this electronic product's production.

20. 1-3 Operator "U" Configured ,Mixed Model Flex cell With Lift Assist

This cell features universal fixturing for multiple models, product lift assist by a single operator and the ability to be staffed by 1 to three operators. A shuttle system provided a simple method for empty fixture and cart return from the end of the cell to the head.

21. ESD Assembly Cell - with Height Adjustable Stations and Redundant Test Bays

ESD Assembly Cell 2020 d1

22. Two Position Mechanical Assembly With Poka-Yoke

A flexible cell incorporating a custom press, universal fixturing and poka-yoke.

23. 4 Station Cell featuring Poka Yoke Kitting and Enhanced Ergonomics

This project involved the mixed model assembly of a heavy product. Objectives included: error proofing, improved production flow, enhanced assembly ergonomics and maximizing space utilization.

24. Worksmart's Multi Bay Test and High Pot Cell

A constriction free, multi-unit, one piece flow, test cell used for high mix production flow.

25. Compact "U" Shaped High Mix Electronic Assembly Cell

See a "U" configured assembly cell with ESD protection that allows the team to work "one ,one down" depending on product mix and production volume. Right sizing delivers maximum space utilization in tight quarters. Powered empty cart return with elevators at each end of the line eliminated operators having to deal with empty carts.

To read this content please select one of the options below:

Please note you do not have access to teaching notes, the broad field of parts presentation.

Assembly Automation

ISSN : 0144-5154

Article publication date: 1 September 1995

Studies parts presentation in manufacturing processes, most of which is now mechanized. Looks at various materials such as metals, paper, springs and food products and how their characteristics affect the way they are presented. Examines the various operations that have to be carried out during presentation including the use of hopperfeeds and vibratory bowl feeders. It is during presentation that parts are often inspected, using types devices including mechanical probes, cameras and optical systems. Looks at parts presentation processes in several industries such as the high speed packaging of pharmaceutical pills, packaging of cigarettes and the manufacture of shirts.

• Part presentation

Wittenberg, G. (1995), "The broad field of parts presentation", Assembly Automation , Vol. 15 No. 3, pp. 8-10. https://doi.org/10.1108/EUM0000000004228

Copyright © 1995, MCB UP Limited

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GEOLEAN FLOW RACKS

Geolean’s engineered material flow solutions include flow racks that solve first in first out (FIFO) and part presentation challenges. Flow racks are an ideal solution for any company looking to optimize their assembly, warehousing, or pick & pack processes. They are designed to eliminate additional transportation steps for parts, and our customized flow racks present parts close to your employees’ workstations to create an ergonomic workspace and reduce repetitive motion injuries.

BENEFITS OF FLOW RACKS

Flow racks designed by Geolean are sized right, to hold only the parts and quantities needed. Along with taking advantage of vertical space to reduce footprint, they are gravity powered to eliminate the cost and flexibility issues of providing power. If you are currently moving parts in large containers, flow racks in combination with implementing small totes will yield significant space savings.

VISUAL ORGANIZATION

Flow racks allow production operators and support personnel to see the product available at a glance. Even if your operation does not have a fully effective pull system in place yet, this visual communication will reduce part shortages that can reduce production efficiency.

Any Geolean flow rack can be constructed with casters to ensure it is mobile and easily moved for cleaning, personnel access, or to another location in your operation.

Geolean flow racks are designed efficiently to use FIFO principles so that new materials are loaded from the back and older material is drawn from the front.

CUSTOMIZABLE

Geolean flow racks offer an unlimited number of customizable designs. No matter your application, industry, loading requirements, line design, or assembly style, our flow racks are designed specifically for you and customized to your precise needs.

Geolean’s engineered material flow solutions are manufactured with our tube and joint assembly system, which means all our flow racks are completely customizable. If you ever need to repurpose or reconfigure a flow rack, it can be as easy as picking up an allen wrench!

RETURN LANES

Returning empty containers without a dedicated method can create a pileup of empty bins or cause your employees to leave their workstations. Geolean flow racks are designed with a return lane to solve that problem so operators can easily return empty containers to the load aisle without leaving their station.

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Geolean flow racks deliver materials efficiently to operators using FIFO principles. They’re customized for your operation’s processes and improve the material flow within your facility by creating a boundary between the delivery aisle and the production area. Our unlimited design options make it easy to support any design requirement, from staggered presentation to over-the-line delivery.

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Does your material flow need improvement we can help, is your factory a good fit for lean integration.

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Lean Assembly Cell Design – 10 Rules

In a video from WorkSmart Systems, learn the 10 rules for assembly cell design based on over 25 years of experience at the time of the video. As you will see, these rules incorporate steps to minimize the 8 wastes.

• One-piece flow with minimum effort
• Balance production and have limited work in process space
• Miniaturize the cell as much as possible
• Provide in process Kanban when necessary
• Proper sequence for assembly
• Division of work
• Line balance
• Straight line
• What equipment or subassembly needs to be integrated?
• Design the workstation to fit the task and the operator
• Use a modular design to make it easy for the operator
• Have tools, supplies, and components within easy reach
• Minimize look and reach time
• Have components at point of use
• Make sure large or bulky components are easily handled
• Standard work procedures
• Method instructions
• Helps minimize rework and WIP
• Stop the line with recurring rework or quality problems
• Eliminate lifting and handling offline
• Keep sight lines open
• Have scalable cell design
• Use Andon lights and scoreboards
• Low/No maintenance
• Easy reconfiguration
• Low first cost
• Economical operation

You can view WorkSmart’s video here .

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Top 10 Manufacturing Best Practices Examples with Samples and Template

Lakshya Khurana

Looking for perfection in creation is a natural human instinct. In business, we extend this quest for the best to manufacturing process, and hunt for the best-practices to ensure we create more wonderful things of all things at the lowest possible cost.

In today’s times, an example of this is automation. It is one of the most cost-effective manufacturing best practices, and is growing at a furious pace, from

$189.7 billion in 2021 to $430 billion in 2023 (according to data published by Acumen Research and Consulting).

Besides automation, there are other manufacturing best practices that can be implemented in your operations to gain distinct benefits and ensuring you are always following the best practice. To help you take your manufacturing processes to their peak, we at SlideTeam, have created this PowerPoint Deck on Manufacturing Best Practices.

Do you wish to present your workflow process visually? Check out our blog here with relevant PPT Slides to teach with sight!

PowerPoint Template to Grease the Wheel

Our PowerPoint Deck is content-ready to give your presentation a framework and 100% customizable and editable. This gives you more flexibility to mold the presentation to your needs. These slides have all the manufacturing best practices from the 5S System to the Zero Defect policy. Let’s take a look at 10 of these methods and look through the slides to give you a taste!

KPI dashboards are your friends when it comes to project status. Click here to access our amazing PPT Slides with readymade dashboards for the manufacturing processes.

Access our Manufacturing and Operations Best Practices Tools & Templates

Template 1: The Five-Step 5S System

The 5S System is an excellent method to streamline the workflow. Use this PPT Deck to communicate the steps in 5S: Sort, Set in Order, Shine, Standardize, and Sustain. The slide bundle goes on to the overview for this process and its application in operations and manufacturing, with appropriate visuals. Download this deck from the link below!

DOWNLOAD NOW

Template 2: You are just in time to Implement Just-in-Time

JIT is a workflow philosophy of pushing the process forward, based on needs from the later steps. Use this PPT Template Bundle to save inventory and warehousing costs with the use of the JIT. The slides help you present the JIT steps for delivery, process flow, and operations and management. Download the PPT Set now.

CLICK HERE TO DOWNLOAD

Template 3: Kaizen

This part in the PPT Set helps you explain and implement the Kaizen Method. This includes slides for the implementation process in Kaizen for operational excellence, manufacturing, and quality improvement. The Japanese know-how to be efficient is an indispensable part of this template. Download this presentation template right away!

GET IT HERE

Template 4: Prevent Waste with Lean Manufacturing

Lean Manufacturing helps you avoid waste processes in your manufacturing operations. Use this PPT Deck to lay down the three pillars of the lean manufacturing process: Quality, Delivery Times, and Cost. Also showcase the parts of the lean manufacturing, some of which are defects, over-processing, over-production, waiting, transport, inventory and motion. Download them now.

Template 5: The RATER Model

RATER stands for Reliable, Assurance, Tangibles, Empathy, and Responsiveness. Use these PowerPoint templates to implement the RATER model to achieve improvement in customer service. Use the five key elements of this model for smooth execution. Download it now.

Template 6: Six Sigma DMAIC Model

The Six Sigma is arguably the most important and prolific manufacturing best practice policy. Use our PPT Slides to present the roadmap that your business will use to implement the six-sigma process for operations and manufacturing. Also provided are the details of the Define, Measure, Analyse, Improve and Control (DMAIC) Model. Download this presentation template right away.

Template 7: Supplier Relationship Management

Risk management, supplier evaluation, supplier monitoring, and supplier development are the four elements that govern the execution of the Supplier Relationship Model. Use this PPT Theme to present these four elements along with the matrix slide for better implementation, and the key risk categories to ensure problem-free manufacturing. Download it now.

Template 8: Total Quality Management (TQM) PPT Template

TQM is yet another prolific manufacturing best practice. It is important for continuous improvement in the process and leadership with the use of its eight key elements. Also provided in the set is the TQM Model for operational efficiency and the key TQM principles as well. Download this deck right away!

Template 9: Value Stream Mapping (VSM) Template Explaining Principles

VSM helps you connect the manufacturing with the customer side of the supply chain. Use these PPT Slides to present the process visually, for value stream mapping and ensure that the end-user receives the product or services they needed/ wanted. Use these slides to present and execute the three-step VSM process and align customer service with manufacturing. Get it now.

Template 10: Zero Defect

Visually showcase the Zero-Defect process from the Research and Development department to the service delivered with these slides. The Zero-Defect Process Workflow as well as the key guidelines provided in this deck help you implement this manufacturing improvement method. Get the slides now!

Only the Best Templates for the Best Practices

More manufacturing best practices such as Kanban boards, KPIs, House of Quality, etc. are provided in this comprehensive PPT Deck. Download it from the links given in the blog! With the manufacturing best practices explained and their implementation process ready, your organization is ready to make your business processes far smoother.

Download our PPT Deck to make these methods a natural part of your manufacturing philosophy.

Looking to optimize your manufacturing process? Click here for the suitable PPT Templates with a blog that adds value.

FAQs on Manufacturing Best Practices

What are some best practices in manufacturing.

Best practices in manufacturing include implementing lean manufacturing principles to minimize waste and increase efficiency, employing quality control measures to ensure consistent product quality, adopting automation and technology to improve productivity, optimizing supply chain management for seamless material flow, and prioritizing continuous improvement through data-driven decision making and employee engagement. These practices help streamline production processes, reduce costs, enhance customer satisfaction, and maintain a competitive edge in the market.

What are the four types of manufacturing operations?

The five main manufacturing processes are:

a) Casting: Pouring molten material into a mold to create a solid object.

b) Forming: Shaping a material into the desired form through processes like forging, extrusion, or rolling.

c) Machining: Using cutting tools and machinery to remove material and create the desired shape.

d) Joining: Combining multiple parts or materials through welding, brazing, soldering, or adhesive bonding.

e) Additive Manufacturing: Building objects layer by layer using 3D printing or similar techniques.

What are the best practices in operations management?

The four types of manufacturing operations are:

a) Make-to-Stock (MTS): Producing goods based on demand forecasts and stocking them for immediate sale.

b) Make-to-Order (MTO): Manufacturing products only after receiving customer orders.

c) Assemble-to-Order (ATO): Preparing standard components in advance and assembling them based on customer specifications.

d) Engineer-to-Order (ETO): Designing and manufacturing unique products tailored to individual customer requirements.

What are the 5 manufacturing processes?

Best practices in operations management involve strategies to improve efficiency and effectiveness. These include implementing robust supply chain management practices, optimizing production planning and scheduling, adopting lean methodologies to eliminate waste, fostering a culture of continuous improvement, using advanced analytics for data-driven decision making, investing in employee training and development, maintaining strong relationships with suppliers and customers, and embracing technology to automate processes. By implementing these practices, organizations can enhance productivity, reduce costs, improve customer satisfaction, and achieve sustainable growth.

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