Fleximate Transport Cells
Lean Manufacturing Cells
OPTIMIZED, MODULAR LEAN ASEMBLY CELL
The Fleximate® Transport System uses a building block approach to create optimized, lean assembly cells. Start with our modular Fleximate® Integrasted Workstations, which are a hybrid of conveyance and an ergonomic workstation that combine the benefits of both. Then connect multiple stations together by their track tubes upon which Fleximate® carts travel with WIP on them. This creates a single piece, production flow, for worker paced, progressive assembly. Additionally, the Fleximate® Integrated Workstations can be customized for test, inspection, rework, and pack out.
The Fleximate® Transport System also has many track configurations and accessories to further optimize lean initiatives. And for the ultimate simplicity and implementation of continuous improvements, our entire system is designed to be set up or modified with a single hex key.
Layout Concepts
Our Modular Fleximate® Transport System stations and track sections can be configured to create custom, lean assembly cells.
To assist in evaluating applications, here are some plan views of various assembly layouts.
The attached drawings show possible configurations of a four-person manufacturing cell. Included is a description of each configuration’s features and benefits. We have shown a four-person cell for simplicity. The cells shown utilize small Fleximate® Integrated Workstations, gates, turnstyles, shuttles and curves. All can be customized to improve on your lean initiatives. The configurations can be expanded for any number of stations and can be utilized not only for assembly but also for test, rework, inspection and packaging.
Concept #1: Straight Line Cell
This type of cell uses minimal floor space. It allows the addition or deletion of stations to balance and rebalance a cell with minimum effort, thereby being able to ramp up or down to meet production volume requirements. Workers can easily work 1 up, 1 down on the line. For higher production volume, a pneumatic lift system is available to raise and lower the work carts from the mail line to return track below the station. This eliminates handling of carts. Parts can be stocked from behind the stations. All of these features improve lean manufacturing by reducing line waste and improving your ability to react and meet customer demand. Call for cart lift system application data.
Shown:
4 – Fleximate® Integrated Workstations, Standing Height, with Return Track P/N 80030
1 – Fleximate® Elevator System (Pair Lift/Lower) P/N 50001
2 – Fleximate® 18” Carts with Tops P/N 80027
1 – Straight Powered Belt for Cart Return w/Motor P/N 50003 & 50004
Concept #2: Rectangle Closed Cell with Shuttles
A closed cell allows for good communication between workers and automatic return of carts to the head of the line, as the assembly process starts and finishes at the same point. Using the shuttles at each end of the cell allows for quick transfer of carts from one side of the line to the other and utilizes less floor space than 90-degree curves. This cell would take up an area of 17’ x 7’.
Shown:
4 – Fleximate® Integrated Workstations, 18” Track, Standing Height w/o Return Track P/N 80032
2 – Fleximate® Shuttles P/N 50000
1 – Fleximate® 18” cart with Top P/N 80027
Concept #3: Four Station Cell "L" Configuration
An “L” configuration can be used to fit into a confined area, go around a corner on the factory floor, and is good for allowing pallets of material to be brought into the area behind the workers. Its openness also provides good station to station communication. At the end of the operation, the empty cart can be returned via a return cart that plugs into the track tubes to eliminate wasteful lifting. For high volume applications, elevators and a lower empty return track can be utilized.
Shown:
4 – Fleximate® Integrated Workstations, Standing Height w/o Return Track P/N 80032
1 – Fleximate® Transport 90-degree Curved Track Section, Standing Height P/N 80022
1 – Fleximate® 18” Cart with Top P/N 80027
Concept #4: Four person U-Shaped Cell with Gate
The “U” shaped cell allows for good communication among workers to solve and prevent problems and maintain quality standards. This configuration allows the worker to be inside and/or outside the cell. If volume ramps up significantly, a closed loop would be retrofitted. An optional transfer cart can be used to return multiple carts to the head of the line, or a powered cart returning on a lower track with elevators on each end could be utilized. Another method of empty cart return would be a shuttle that traverses the opening of the “U” and would eliminate handling of the empty cart.
Shown:
4 – Fleximate® Integrated Workstations, standing height w/o Return Track P/N 80032
2 – Fleximate® Transport 90-Degree Curved Track Sections, standing height w/o return tracks P/N 80010
1 – Fleximate® Transport Gate, Standing Height P/N 60007
3 – Fleximate® Carts with Top 18” Track 80027
Concept #5: Four Person Cell “Oval” Continuous Loop
This scheme allows for the progressive return of the cart to the head of the line and has many of the benefits of Concept 2. Assembly, test and/or packaging can be done on the curve sections of track (an integrated station is shown in the 180-Degree Curve). This type of cell is good for all levels of production volume when handling the carts is not desirable. It also provides good station to station communication.
Shown:
4 – Fleximate® Integrated Workstations, 18” Track, Standing Height, w/o Return Track P/N 80032
4 – Fleximate® 90-Degree Curved Track Sections, Standing Height w/o Return Track P/N 80022
Concept #6: Four Person Cell with Shuttle and Turnstyle for Taking Product Off-Line
This configuration shows two methods of taking products off-line. The turnstyle allows a small section of track to be turned 90-degrees to the main line to transfer the work cart off-line. It can also be used to make a 90-degree change in direction in a tight corner. The shuttle is a second way to transfer products off-line. This uses a shuttle cart, which carries the work cart and product, off-line for test and rework. Both methods of taking products off-line allow for duplicate tasks to be performed online without bottleneck.
Shown:
4 – Fleximate® Integrated Workstations, 18” Track, Standing Height w/o Return Tracks P/N 80032
1 – Fleximate® Shuttle Track, 18” Track, Standing Height P/N 50000
1 – Fleximate® Turnstyle, 18” Track, Standing Height P/N 50002
