Existing work tables could hardly be changed

SIKO's measuring devices and systems consist of many individual components that are assembled into modules and finally into end products in several assembly operations. The existing work tables in the production hall at the Buchenbach site came from different manufacturers and could not be flexibly adapted to different requirements. It was also difficult to keep different profiles in stock. "We wanted to commit to one manufacturer in order to optimize our warehousing," says the Head of Lean Management at SIKO. "With item, we can produce standard tables quickly and efficiently, make flexible adjustments, integrate accessories and configure individual systems."

Superstructures and long assembly lines

The joint project started at the end of 2016 with Cardboard Engineering. "We used a cardboard model to recreate our assembly line," says the lean expert at SIKO. "In the spirit of lean production, we wanted to develop low-waste work and material flow systems and implemented new ideas and proposed solutions directly on the model as a team." Following the design phase, a prototype was created with direct support from item. To create an assembly, the employee takes individual parts from various containers. With the help of superstructures at existing workstations, the material was to be brought to the employee's gripping area for production. "Originally, the material was at the back of the assembly workers," reports the SIKO employee. "That was neither ergonomic nor efficient." SIKO was looking for a solution to separate logistics from value creation. In addition, the entire production process needed to be optimized. The problem: if the 2 to 3 meter long workbenches are arranged in a row, the employee has to cover a long distance while carrying out the individual work steps. Once they have completed their assembly at the end of the row of tables, they have to return to the beginning of the row.

U-Shape leads to optimized workflows

SIKO decided to switch completely to item work benches at the new site. Once the number and size of the containers had been determined, item designed the size and structure of the workbenches and configured other components such as roller conveyors. "Once item had completed the design, we checked whether all our requirements had been met. The 3D illustration was particularly helpful," says the person responsible at SIKO. In addition to the item work benches based on standardized dimensions, SIKO also uses narrower special benches. These tables are available for testing and packaging processes, while the standard tables are used for pre-assembly and main assembly. The measuring device manufacturer uses various special components from item for the standard tables. For example, material feeds are implemented in the form of roller conveyors. The item work tables are set up in a U-shape in the production areas. This arrangement results in ergonomically optimized work processes. Employees only need to walk a short distance for the entire work process, from assembly to product packaging. "The rational arrangement of the tables offers considerable advantages for the employees," reports the lean expert. "We also saved a lot of space by reducing material stocks and the material flow-oriented arrangement."

Individual settings and maximum ergonomics

In addition to production areas, SIKO also uses item workstation systems in production-related areas such as the workshop and technicians' offices. The desks are height-adjustable and can therefore be perfectly adapted to the height of each individual employee. The ideal height is saved and can be recalled at any time. All desks in a U-Shape move simultaneously to the programmed height thanks to the integrated synchronized control. When employees change, the ideal setting can be recalled within a very short time. This means that employees always have optimum ergonomic working conditions. The item SystemMobiles L and U are an ideal addition to the workstations for transporting materials. Logistics staff use them to transport components for assembly from the incoming goods department and the warehouse to the relevant workstation. Small components that are used less frequently in a U-Line but are still required for special variants are stored in other SystemMobiles. This enables the employee to change over the workstation as quickly as possible and independently. In this way, SIKO ensures that, in addition to ergonomics, special variants can also be built in the shortest possible time.

Flexible design convinces

SIKO is a manufacturer of variants. Many different components need to be available at the workstation. A flexible arrangement of tables with different dimensions is essential for the efficient production of measuring devices and systems, which is why SIKO benefits from the many possible combinations of item components. These are compatible with each other and can be attached flexibly. This means that the standard tables can be modified quickly and with minimal effort, even for small batch sizes. SIKO stocks some profiles and accessories, such as keyboard holders, hooks or magnets, in the respective workshops at both locations. If additional components are required, item delivers them within 24 hours. "This allows us to change our production at short notice and adapt to changing requirements," explains the lean expert. "Another advantage is the catalog with the numerous products that item provides on its website."

Lean philosophy optimally implemented

From the start of the project to the first delivery of the U-Shapes, SIKO made constant adjustments and was in close contact with item to ensure maximum ergonomics and efficiency. The biggest challenge was managing the large project volume within the given timeframe. "Although so many people were involved in the project, the process ran smoothly," emphasizes the Head of Lean Management. "An example of perfect implementation of the lean philosophy."