Automation at the Cellular Manufacturing Level Transformed with New Innovations

MATERIAL HANDLING TECHNOLOGY

Too often the idea of automation in large manufacturing facilities starts with pre-conceived robotics imagery. Ironically the simplicity of new automation technology can be viewed at the manufacturing cellular level, rather than the entire plant floor.

A manufacturing cell is an efficient grouping of all the resources required to manufacture a product. These resources, which usually include people, supplies, machines, tools, and other production equipment, are arranged in close proximity to enhance communication and allows everyone to see what is going on at all times.

Modern Machine Shop reviewed cellular level manufacturing more than a decade ago and concluded then what is still known today, namely that cellular manufacturing is a tried and true process that has reduced product costs, while improving lead times and quality. Cells have prospered because they work, and they work in almost any type of Processing a part more than is required to make it function properly is another form of waste. Cells address the waste of over processing through close proximity of all processes and the strategy of only making what can be used. Unnecessary processes such as packing and unpacking are eliminated because handling is reduced, and that which remains poses little risk of damage. Parts in the cells are processed sooner, so any of the other product protection processes can also be eliminated. The close proximity of all the operations makes it easier to identify the processes that are not adding value to the product.

There is significant wasted motion in a typical manufacturing process. This often results from a poorly organized work area. By putting everything together in a manufacturing cell, wasted motion can be reduced, if not eliminated entirely. Eliminating travel to other areas to get parts is an obvious improvement, but what cannot be underestimated is the reduction of motion within an individual process. With a well-designed cellular operation, motion shifts from non-value added to value added. When emphasis is placed on conveniently locating everything that operators need to do their jobs, much wasted motion is eliminated.

One of the most common causes of waiting is an unbalanced workload. Manufacturing cells can reduce waiting by supporting more synchronized flow. With all the required resources grouped closely together, synchronized product flow is easier. Worker flexibility within the cell will also help reduce waiting time because operators can help others when they are not busy.

Transporting a part through the shop is a wasted effort. A manufacturing cell can reduce part transportation because the close proximity of the cell's resources makes part transportation almost non-existent. As a result, material handling equipment can be reduced or eliminated altogether.

Technology innovator Magline, best known for two-wheel hand trucks used in the beverage industry, has solved the tool and die heavy lifting problem in manufacturing facilities. Magline's LiftPlus provides an all-in-one lift, transporter, and positioner. The LiftPlus is a workforce multiplier that kicks in productivity with no need for special training or licensing. The LiftPlus was designed for ease of use, higher productivity, and to keep workers on the job and free from injuries; lifting 350 pounds easily with an all-metal frame platform and a screw-driven lift that delivers smooth precision that hydraulics or chains just cannot match.

Waiting for a forklifts to move product in a manufacturing cell is eliminated. Andrea Horner, Magline's vice president of marketing stated, “This powered product demonstrates a commitment to the manufacturing sector and those customers who requested durable, ergonomic, and quality equipment allowing safe use and transport without wasting time waiting for forklifts. The improved throughput and productivity is a direct result of time efficiencies achieved with the LiftPlus within the manufacturing cell.”

To view a video of the LiftPlus, go to: http://bit.ly/1rJ6pSM

Eliminated Fork Trucks to Maximize Manufacturing Work Cells

 

LiftPlus           

 Fork Truck

Investment

Low

 High

OSHA Certification Required

No

 Yes

License Required

No

 Yes

Turning Diameter

6 Feet

18.5 Feet

Space Required

Minimum

Maximum

Fuel Required

No

Yes

Accessories/Other Applications

Yes

No

Fork Truck Free

Yes

No

Article Courtesy:

Thomas R. Cutler

Author Profile:

Thomas R. Cutler is the President & CEO of Fort Lauderdale, Florida-based, TR Cutler, Inc., (www.trcutlerinc.com) Cutler is the founder of the Manufacturing Media Consortium including more than 6000 journalists, editors, and economists writing about trends in manufacturing, industry, material handling, & process improvement. Cutler authors more than 500 feature articles annually regarding the manufacturing sector and is the most published freelance industrial journalist worldwide. Cutler can be contacted at This email address is being protected from spambots. You need JavaScript enabled to view it. and can be followed on Twitter @ThomasRCutler.

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