To meet our customers rising manufacturing requirements, Worksmart Systems was approached with a production puzzle: How to create a lean cell with enhanced, worker paced product flow and product manipulation for a heavy transmission? A third requirement was that a matched set of components had to be segregated, which complicated parts presentation.
In our discussions, it was clear, that the system had to be both robust and simple. Our experience had proven that an oval configured cell, utilizing our modular Fleximate Transport system of production flowing on a cart, would provide a scalable foundation for a worker-paced cell. It would also have the ability to easily integrate tooling, fixtures and metrology equipment. A further benefit would be that the finished product would end at the beginning of the cell, thereby eliminating wasteful handling of the fixture and cart.
Once the layout was determined, we set about creating a fixture design that would yield maximum efficiency. As the heavy assembly needed to be accessed from two planes, we decided that a trunion fixture would be required to provide mechanical advantage to manipulate, position and lock the product during assembly. A manual reduction gearbox would be a part of the fixture design. To further assist assembly, the entire fixture could be rotated perpendicular to the line and locked in place with pneumatic cylinders activated by foot pedals.
Having solved production flow until the Fleximate transport line and product handling, with the trunion fixture, there was one remaining requirement. How to maintain matching component sets, which made lineside parts presentation unsuitable? Our novel approach was to kit the matching sets and display them on a trailer, which would be tethered to the trunion fixture cart. Each trailer was equipped with non-marring details and nests for the matching components.
An added benefit of the modular cell was presented when the ramp up for production was shortened. We were able to ship the cell, door to door in large components, providing the customers team with a fast set up and extra time to integrate their various systems.
Production flow, product handling and parts presentation: turnkey lean solutions from Worksmart Systems.
