Lean Equipment

The initial investment in converting to lean can be less than $10,000. Obviously it’s not realistic to revise an entire plant for that amount, but there are small steps that can pay immediate dividends.

The best lean assembly lines are supported by modular material handling systems. These systems are made up of pipe/rack structures that are simple, mobile, adjustable, reusable and temporary. These structures, such as workstations, flow racks, and mobile carts, help operators eliminate waste and increase production while performing a job.

Simple. Ideally, material handling structures alongside an assembly line should be constructed of fundamental components. The drawings required to make the structures should be elementary, and only basic tools and skills should be necessary to assemble the structures. If required, an operator should be able to create a structure to solve a problem independently within hours of identifying the situation’s requirements.

Mobile. Material handling structures should be easily relocated. If the workstation needs cleaning, the material handing structure should easily be rolled out of the way so the floor can be swept.

Adaptable. For certain, customers, products and demand will all change. These structures must be adaptable to these changes.

Re usability. On mass production lines, structures are welded and painted for onetime use. With reusable structures, a flow rack one day could become a table or a cart the next.

Temporary. Ideally, structures should be designed and built to last just for the current product’s life cycle or until the next improvement is implemented. This is not to say that the components themselves should not be extremely durable.

An effective material handling system must meet all of the above criteria. In addition, the flexibility of the system empowers the employees, as it generates ideas and encourages creative thinking. Employees can investigate more effective methods of using a material handling system in performing tasks. Having the power to implement positive change is a strong intangible—people enjoy working in that environment.

Facility size isn’t a factor in deciding to use lean material handling systems. They work as effectively for manufacturers that employ thousands as they do for plants with less than 25 employees.

There is no definitive blueprint for a lean plant. There are lean plants that do not use material handling systems, just as there are mass production plants that do use them. However, to achieve the greatest value in manufacturing, the most beneficial combination is a lean philosophy that relies on a material handling system to help eliminate waste and promote continuous improvement. In other words, a lean line and methodologies are an effective method for improving the bottom line.

For more information or for a free material flow consultation visit, please contact Robert Jones at Lean-Stream (Robert@lean-stream.com).

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