Case Study: item Work Stations Improve Production by 150%
Semi Automated Assembly Line-SAAL 2000
This customer is a global organization that manufactures quick disconnect couplings, hydraulic and solenoid valves, lay-flat hose, high pressure valves, vessels, reactors and fittings that provides expert solutions matched to the needs of each use and application.
There was a need to significantly increase both the output and efficiency of the manufacturing process through the introduction of lean automation practices.
item engineers worked closely with in-house manufacturing engineers to design a variable speed pallet conveyor system (elcom) and a number of test stations and flexible workstations.
Within weeks of the initial design approval, item delivered an operator-controlled assembly line that exceeded the expectations of corporate management.
This line is used to produce a single family of valves with over 60 different model variations.
This new automation cell increased production by 150% or 2.5 times previous production. Current production is now approximately 20,000 units per month.
Hex Valve Assembly Line
item’s success on the SAAL 2000 line resulted in a similar concept for hex shaped valves. Hex shaped valves are offered in 15 different model designs which contribute to the complexity of assembly.
Lean manufacturing ideas for this line combined both elcom flat belt conveyors and gravity fed returns for design simplicity and reduction of initial automation costs.
Once again, item’s design resulted in a 150% increase or 2.5 times the previous assembly line production. This three workstation assembly line produces just over 15,000 hex valves per month.
Both assembly lines have significantly improved the flow of production while contributing to a balanced manufacturing system.
A third assembly line is currently in the planning stages. This third line is expected to contain four different workstation assembly areas and should be introduced in 6-12 months.
According to plant management, there has been a significant cost and labor savings as a result of these assembly lines and the support from item North America.
