Case Study Videos

Worksmart Systems doesn’t just talk “Lean Manufacturing”, we help your team create a “Lean Assembly Cell” or Ergonomic Workstations to your specifications. Additionally, we can provide systems integration to enhance the cell’s operation.

For a clear view of our features and benefits, we offer a library of Case Study Videos of installations. They are grouped by types to provide focus on how Worksmart Systems can be your solution.

Fleximate® Transport Systems: Integrated Stations with Carts and Tracks

This product is our Hybrid Ergonomic Workstation and Conveyor. Stations are joined together by track tubes and the WIP flows through the stations on Transport Carts rolling on the track tubes. We have two standard track/cart widths 12” and 18”. Our standard cart weight capacities are either 75 or 150# depending on your requirements. An auxiliary worksurface is available with our Flowmate® option. The system can also be customized as required. The following videos depict standard and customized stations, carts and cells.

1. Fleximate Transport Line - Straight ESD Cell with Single Unit Flow, and on Line Test

This 100 foot long cell is an example of a straight ESD cell with single unit flow and on line test for a high volume electro-mechanical product. Other features include custom fixtures, a powered empty cart return, lift and lowering elevators at each end of the cell and mobile parts flowracks.

2. Fleximate Transport Line - Custom pallet cell for a 350# product with a 30" x 39" foot print. 11 Positions in a 100 foot long line

This cell features single piece production with improved ergonomics, supermarket parts presentation, tool handling, on line test and many other enhancements. Other options include, height adjustability, fixturing, error proofing, elevators and automated empty pallet return.

3. Fleximate Transport Line - Oval Configuration with Custom Trunion Fixture

This cell produces a heavy mechanical product. Our fixturing provided manipulation and rotation in two planes which combined with a optimized track height provided efficient worker ergonomics and simple product transfer.

4. Fleximate Transport Line - "S" Configured Cells in a Clean Room Environment

Two long cells for a 250# product. The unique cart design enabled operators to on line inspect for QC. Production flow was a combination of free and powered conveyance.

5. Fleximate Transport Line - Lean Assembly Cell Straight Line

Two custom Fleximate cells featuring unique overhead return of empty pallets due to unique fixturing. Cart tops featured rotation for this high volume automotive application.

6. Fleximate Transport Line - Clean Room Oval Configured Cell with In Line Oven Integration

This application includes a progressive flow through a low temperature oven in a clean room. Also featured is a post cure powered, section for cool down, Custom workstations were integrated into the line to minimize handling of the heavy product and fixture.

7. Fleximate Transport Line - Oval Cell Configuration with Unique Fixturing

This complex mechanical assembly required some fresh thinking for multi access assembly. Custom work surfaces assisted in worker ergonomics and assembly productivity.

8. Fleximate Transport Line - Oval Configuration for a Heavy Product with unique Parts Kitting Capability

This cell featured a re-manufactured product which required that all reused components remain together. We provided a means of keeping the family of parts together with the product housing.

9. Fleximate Transport Line - Mixed Model Cell in Straight Configuration with Supermarket Parts Presentation

On line supermarket parts presentation supporting a high volume, high mix production schedule.

10. Fleximate Pallet Slide Lines - Twin Parallel Straight Cells for a 400# Product

Two sliding pallet cells featuring custom tool presentation, poke yoke, universal fixturing details, and custom power, signal and air distribution. Automated pallet return with elevators and ESD control were other design criteria.

11. Fleximate Transport Line - Mixed Model, Single Piece Flow in a Straight Line

In this application, fixturing and parts presentation was created to produce completely different products. Sub assembly stations produced at point of use with quick change over capability to support mixed model flow. An overhead lift with a lifting yoke made packaging a safe, single operator operation.

12. Fleximate Pallet Slide Line - Short Takt Time, Mixed Model Production in a Straight Line

This cell was designed to handle a wide range of product sizes by incorporating some unique controls and varied parts presentation.

13. Fleximate Pallet Slide Line - Low Effort Sllde Line for a Mechanical Product Family weighing up to 900#

A low volume product that was transitioned from batch to progressive assembly. Unique challenges included height adjustability, multi product, quick change, adapter plates and inline leak testing.

14. Fleximate Transport Line - "L" Configured Cell with Integrated Ergonomic Product Manipulator

Electro mechanical assembly cell with fixturing challenges. Also included was a product tilt assist that transitioned the process from an unsafe, two operator lift to a semi automated, single operator, ergonomic operation.

15. Fleximate Transport Line - High Torque Production in a Straight Line with A Turnstyle feeding Two Test Bays

This cell successfully transitioned a high mix, low volume production from batch to single piece, progressive production. The design wish list included the ability to handle high torque assembly, dual test bays with out production constrictions and an anti-tip safety feature.

16. Fleximate Transport Line - Straight Cell Incorporating Ergonomic Fixturing to assist Assembly

An in depth assembly examination yielded some beneficial fixture considerations. An end of cell, lifting arrangement made packaging a safe, single operator process.

17. Fleximate Transport Line - Straight Cell with Mechanical Assist Product Manipulation

This mature product was transitioning to a single piece flow with standard work procedures. We incorporated ergonomic fixtures and a high pressure test process in line and yielded high productivity.

18. Fleximate Slide Line - Transition from Batch Production for a Heavy Product Family. Cruciform Layout

This cell featured a stainless steel fixture plate rolling on custom roller tracks with multiple safety features for up to a 1200# product. The high mix, low volume product line required height adjustability, low effort, production flow, and multiple test bays. A powered turntable allowed production to flow, uninterrupted, into one of three test positions.

19. Fleximate Transport Line - A "U" configured Cell with Stringent ESD Control Requirements

Multiple work height stations, high performance ESD control and integration of a UV cure tunnel were just a few of the requirements for this electronic product's production.

20. 1-3 Operator "U" Configured, Mixed Model Flex Cell with Lift Assist

This cell features universal fixturing for multiple models, product lift assist by a single operator and the ability to be staffed by 1 to three operators. A shuttle system provided a simple method for empty fixture and cart return from the end of the cell to the head.

21. ESD Assembly Cell - with Height Adjustable Stations and Redundant Test Bays

ESD Assembly Cell 2020 d1

22. Two Position Mechanical Assembly With Poka-Yoke

A flexible cell incorporating a custom press, universal fixturing and poka-yoke.

23. 4 Station Cell featuring Poka Yoke Kitting and Enhanced Ergonomics

This project involved the mixed model assembly of a heavy product. Objectives included: error proofing, improved production flow, enhanced assembly ergonomics and maximizing space utilization.

24. Worksmart's Multi Bay Test and High Pot Cell

A constriction free, multi-unit, one piece flow, test cell used for high mix production flow.

25. Compact "U" Shaped High Mix Electronic Assembly Cell

See a "U" configured assembly cell with ESD protection that allows the team to work "one ,one down" depending on product mix and production volume. Right sizing delivers maximum space utilization in tight quarters. Powered empty cart return with elevators at each end of the line eliminated operators having to deal with empty carts.

26. Compact 6 Position Lean Assembly Cell

A right sized cell for a 100 pound product that single piece flows to point of use.

27. Progressive Assembly of Mixed Model Control Panels

Lean sub assembly cells feature single piece production flow, ergonomics, on-line test and line side, point of use presentation.

28. Fleximate Flex Line: A Synchronous, Asynchronous, Mixed Model ESD, U Cell with Automate Test

Worksmart Systems' modular Fleximate Integrated Workstations are the answer for simple DIY Cell construction. They can also be the basis for automation and system integration as shown in this video. Simple, complex or in between, Worksmart has your production solution.

29. Powered Synchronous Flow, High Mix Lean Production Cell

This unique 6 position, assembly cell features pallets flowing on ESD timing belts and individualized ergonomic height adjustable workstations. Other custom design enhancements include quick change tooling to support real time, mixed model production changeovers, on-line test and component shadow boards for poka yoke assembly.

FLEXIMATE® INTEGRATED WORKSTATIONS, CARTS & OPTIONS:

STATION COMPONENTS

Fleximate® Workbenches

Case Study Videos

Fleximate® Transport Systems: Integrated Stations with Carts and Tracks

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FLEXIMATE® INTEGRATED WORKSTATIONS, CARTS & OPTIONS:

STATION COMPONENTS

Fleximate® Workbenches