When we started to assemble the components, we noticed that the Flexpipe system was sturdier and that the pipes were thicker.”
Flexpipe helped us with the flow cart designs and tube-cutting list and did the follow-up. Here’s what they told us about their reasons for choosing the Flexpipe material handling system: ‘’With other brands, you do not get the same service. The HRE production team is now planning to dismantle some of the excess carts to build something else with the components, such as an operator desk.īefore using Flexpipe, HRE tried another system, but its performance fell short of expectations. With the kitting flow carts, HRE reduced WIP (“work in progress”) by 25%-and realized that they built too many carts! This happened because they based the cart construction on the old WIP. Bringing the workstations together has consequently reduced walking and handling times. Now, with one-piece flow kitting carts, 50% of the floor space has been recovered, allowing the quality control station, the assembly line, and the packaging spaces to be closer together. The new carts offer better staging, better flow, better order tracking, and greater visual management, thanks to the color coding and the first-in-first-out floor marking for the carts.īatching parts was taking up a considerable amount of space, especially in the assembly area. The production manager now saves 4 hours a day.
Since implementing the material handling system, HRE has cut its lead time by 50%, resulting in less handling and less time wasted looking for misplaced parts. The results: lead time and assembly floor space reduced by 50% One of my best days working here was when I took a sledgehammer to the old steel racking The work order followed the flow cart on a simple hook that could not be removed.įurthermore, red kitting carts were dedicated to rush orders for clients paying the rush fee, and blue kitting carts were devoted to return goods authorization. Each order had its black kitting cart, creating a one-piece flow effect in the factory. The solution: a kitting cart for each orderĮven though workers were a bit skeptical, the production manager prototyped and tested a modular tube and joint kitting cart to fit a 4-wheel order perfectly. Supervisor – HRE Performance Wheels factory We were spending a lot of time loading and unloading parts to pallets/carts/shelving, and we were spending considerable time searching for parts Download the PDF or image version of this case study
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