Production increased from 3 heat pumps to 6. However, the number of employees remained unchanged.
Read how we helped streamline the production process in a brand new production hall using lean manufacturing. The pipe system helped to increase productivity, but also the satisfaction of employees and company management.
Implementation of lean production: modification of the production process with regard to ergonomics
Heat pumps were originally manufactured in an old textile factory, where approximately 3 pumps per day were produced on several floors of the building. The management of the company decided to build a completely new production hall with a clear goal - to produce up to 6 pumps a day in one shift in the new space. And that with a constant number of employees.
First, the company wanted to order classic welded tables. However, after the visit, the Enprag team recommended a tailor-made solution from a pipe system. At the beginning of the project was the determination of the expected daily production capacity and the description of the current production process.
"With Enprag, we subsequently adjusted the entire production process and transferred it to reality using lean production. The sequence of production operations was changed in such a way that the individual operations were connected to each other smoothly and the material flow was reduced to a minimum. Enprag also discussed the changes directly with the employees - they asked them, for example, whether they stand or sit while working, or what tools they use. Everything was then finally coordinated with regard to ergonomics and speeding up production," explains the production manager.
An example of speeding up the production process is the easier movement of the product between individual production operations. Originally, the product was moved on a pallet using a pallet truck. But there was a constant shortage of pallets, which caused complications in operation. After the implementation of lean manufacturing, the product is moved between individual production operations using a trolley from a pipe system.
“The system is also more friendly to people - we don't have to force them to adapt to a welded table from a catalogue. On the contrary, we "tailor" a table for them, including storage areas or holders for tools. Thanks to the variability of the solution, we cooperate with Enprag even after delivery. All I have to do is take a picture of the workplace where the equipment needs to be added, and the request is immediately assigned to the saved drawing, and the change can be made quickly."
Tubular modular system: economical and variable solution
When making decisions, the company's management was helped by visualization, thanks to which they were able to visualize the entire solution and its benefits.
"As management, we perceive two main advantages of the pipe system. Its variability - as we want to continue to grow and add another hall, we can add anything to the existing applications.Or, on the contrary, disassemble them and use the material for a new workplace. The second advantage is a good price, despite the fact that these are atypical solutions. Looking back on the whole project, we can see that working with Enprag was a good decision."
After moving production to the new hall, production increased from 3 pieces of heat pumps to 6 with a constant number of employees. In addition, further increases are planned. Thanks to lean production and the ergonomic layout of workplaces, employees are happier, more productive, and they also come up with ideas for further slimming. The pipe system was able to perfectly adapt to both the new space and the production process.