Lean ManufacturingStorage Guidebook

Contents

Introduction to

Lean Manufacturing Storage . . . . . . . 2

How to Implement a 5S Program

for your workstation . . . . . . . . . . . . . . 3

How to Implement One Piece

Flows with Cell Manufacturing . . . . . 4

Manufacturing Supermarkets . . . . . . . 5

UNEX Flow Cell Information,

specifications and examples . . . . 6-10

UNEX Case Study:

Toyotetsu . . . . . . . . . . . . . . . . . . . . . 11-12

UNEX Case Study:

Johnson Controls . . . . . . . . . . . . . 13-14

UNEX Case Study:

Android Industries . . . . . . . . . . . . 15-16

UNEX MANUFACTURING, INC.691 New Hampshire Avenue, Lakewood, NJ 08701

800.695.SPAN (7726)732-928-2800 • fax: 732-928-2828

e-mail: span@unex.com

@unex

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com

Thank you for your interest in UNEX Manufacturing’sGuidebook to Lean Manufacturing Storage.

Lean manufacturing is an amalgamation of manufacturing methods that focus on eliminatingnon-value added activities, and aims to deliver high-quality products on time at the lowest costand with the greatest efficiency.

Since the beginning of the 21st century, UNEX Manufacturing has been laser-focused ondeveloping and engineering solutions that help bring lean principles to our customers’manufacturing processes. From workstations to flow racks, UNEX has created multiplecustomized solutions that eliminate waste while increasing efficiency. This leads to qualityproducts, low production costs, and, most importantly - very happy customers.

In this guidebook, we will discuss several lean principles like the 5S philosophy, one piece flow,and manufacturing supermarkets. We will also highlight UNEX solutions that help yousuccessfully implement these strategies. Finally, we will show these solutions at work inlean facilities all over North America.

The UNEX team is always ready to help you streamline your processes and successfullyimplement lean manufacturing principles in your facility. You can contact our team of expertsat 800-695-SPAN (7726) or span@unex.com to learn more about UNEX’s lean solutions orto request a quote.

About UNEXFounded in 1964, UNEX is a family owned business and the trusted industry leader in providinginnovative order picking solutions that maximize space usage, increase pick rates and improveergonomics at the point of pick. Our Pickologists design and provide engineering support forall our products with one goal in mind: to help customers keep processes and profits flowing.

UNEX is an ISO-certified company committed to quality and bringing value to our customers.Our goal is to exceed customer expectations through continuous improvement, customer serviceand empowering our employees.

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 2

躾The 5S philosophy outlined below will guide you through implementing the program on in yourwork station. While you’re reading this guide, visualize your workstation and think about howthese steps can be applied to the specifics of your operation.

Seiri 整理The first S translates loosely into SORT. To begin, remove all items from the work area.Inspect all equipment and identify all items critical to the success of the function performed in aparticular area. Eliminate duplicates, unnecessary equipment, infrequently used items, and trash.Identify these non essential items as waste or non critical, but valuable. Dispose or store thisequipment out of the workstation area.

Seiton 整頓The second S is Set (in place). For this step, take the equipment that will be staying in theworkstation area and organize it. Assign positions for all equipment, WIP, and raw materials,keeping in mind: ease of reach, identification, proximity to use. The idea in this step is tomaximize the efficiency of your layout. Think about how you perform your job and howtweaking the location of your equipment could make you more productive.

Seisō 清掃Step 3 is translates to Shine. This step is all about cleaning. Clean the floors, the walls, and theequipment and ensure all items are restored to their designated place. Shine should be a partof everyone’s daily tasks and should not be put off until idle time is available.

Seiketsu 清潔The 4th S is Standardize. Develop standardized work procedures for the prior 3 S’s. Ensure allworkers understand their responsibilities and are empowered to perform all tasks. Assign anarea in your facility for storing of non essential equipment identified in Sort and apply the5S philosophy to that area as well.

Shitsuke 躾Finally, Sustain. This is the never ending step of ensuring the 4S’s continue to be implementedand that you don’t slip back into your old ways. Commit to performing these steps every shift.This ensures that problems alleviated almost as quickly as they’re created and changes toproduction are compensated for at your workstation. Continuous improvement!

When complete, the result is a safe, lean and clean workstation where with an optimizedworkflow and where problems are easily identified. It’s easy to spot missing tools, empty flowracks, safety hazards and overproduction. You’ll also be happier, working in an environmentthat you’ve taken ownership of, optimized, and made your job exponentially easier.

How To Implementa 5S program foryour workstation

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 3

Implementing one piece flow with U-shaped manufacturingcells is a great way to eliminate waste in most manufactur-ing environments with moderate amounts of variabilityin production size and product mix. One piece flow willhave a tremendous impact on manufacturing lead times,production delays, inventory levels, and warehousingspace requirements.

Some of the key concepts to understand when transition-ing to a manufacturing cell are: one piece flow, line balanc-ing, right sizing, ergonomics, and quality control.

One piece flow, the opposite of batch processing, is themovement of a single product through the manufacturingprocess. One piece flow redirects the workforce away fromnon-value added activities (waste) and focuses on themanufacturing process. With batch processing, largeamounts of wastes exist in waiting, transporting, andstorage of inventory. Workers maximize their outputat the expense of downstream processes and increasedwork in process.

With one piece flow, the work in progress (WIP) is drasti-cally reduced which minimizes exposure to defects in themanufacturing process and allows for quicker reaction tofluctuating customer demands.

One piece flow creates a smoother production process,with steady workloads and shorter lead times. It’s impor-tant the units of work performed in each position haveequivalent cycle times in order to keep the processsmooth. This technique is called “Line Balancing”.

Right sizing machinery to meet customer demand, insteadof minimizing part cost, is essential to the success of cellu-lar manufacturing. Placing smaller and slower equipment inclose proximity to other equipment and processes helpseliminate wasted space, walking, inventory build-up andlower initial cost.

Cellular manufacturing is a system to transfer productsbetween stations (i.e. U, J, or L shaped cell), a method tofeed parts into the stations (flow racks, bins, or carts),and a means by which to flow finished goods andpackaging out of the system.

Set Up Tips• Always flow product in the same direction,

counterclockwise.• Cross train employees to be able to perform all

or most functions within the cell to increaseresponsibility, quality, and traceability.

• Use a U shaped cell when possible to minimizethe distance between the beginning and theend of the process.

• Use First In First Out (FIFO) to shorten lead times,reduce errors, and improve order accuracy.

• Position workstations as close together aspossible to eliminate wasted space but not soclose as to hinder maintenance or creatediscomfort for employees.

• Create a system for flowing sub parts into thesystem in an optimal manner, consideringergonomic principles.

• Keep the path of flow within the cell clear andunhindered.

The benefits of implementing cellular manufacturing in theappropriate environments can have a positive impact on abusiness. Reconfiguring machinery into cells reducesmaterial handling and warehouse footprint. When properlyexecuted, a company will simultaneously shorten their leadtimes and dramatically reduce work in process inventory.Having a cross trained workforce gives a factory increasedflexibility to meet variations in demand and a betterunderstanding of a quality product.

How To Implement One-PieceFlows With Cell Manufacturing

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 4

A manufacturing supermarket is comprised ofintermediary storage on the production floor, and isaimed at reducing transportation waste by placingbulk storage of parts as close to the lineside aspossible, without being lineside.

A manufacturing supermarket mimics the function-ality of a retail supermarket. Your factory workerspull components from shelves as they are neededfor manufacturing. It works by creating miniaturestock locations close to your assembly lines, allow-ing the lines to be replenished quickly and easily bytugger or manual carts, eliminating the need forfork truck traffic in personnel areas.

In the 1950’s, Toyota sent a delegation to the UnitedStates to study and replicate America’s mass-pro-duction techniques. However, inspiration struck notin a manufacturing facility, but a Piggly Wigglysupermarket. At the grocery store, the delegationsaw customers serving themselves from shelves.These shelves would be replenished as needed.Seems pretty mundane, right? However, what wesee as standard operating procedure at any grocerystore in America was a revelation to the Toyotateam. What they saw was a system where theamount of product stocked on the shelves wasdictated by demand. The product could bereplenished from a nearby storage room withoutthe need to order more or put the entire inventoryof said product on the shelf.

How does this translate to manufacturing? Toyotarealized that in order to reduce waste, they neededto store just enough of a part or material in anear-lineside position to meet the demand of theoperation - to condense their assembly line. If theyplaced their entire inventory of a part on the line,they would dramatically increase travel time to thenext step in the assembly line. This travel timeresults in a lot of waste. Additional wasteful non-value added activity would occur if they had totravel all the way across the facility to restock apart on the line. The solution was to create a“storage room” as close to the assembly line aspossible.

ManufacturingSupermarkets

And so the manufacturing supermarket was born.Toyota created a process where lineside storagecould be replenished from intermediary storageplaced as close to the assembly line as possible.This drastically reduces wastes, such as overproduc-tion, waiting, transportation, and motion. Think of itlike a miniature distribution center within a shortdistance of your manufacturing processes.Instead of having to ship in more parts or crowdyour assembly line, you can simply replenish yourlineside storage as needed throughout the shiftfrom your dedicated miniature DC.

Set Up Tips• Utilize engineered structures that address your

unique storage needs.• Implement solutions that flow and store totes,

boxes and loose parts of all shapes and sizes.• Create tilted angle trays and knuckle tracks

to deliver the most efficient and safe pickfor your workers

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 5

Cell Capacity1000 lbs per level – at 8 feet wide3000 lbs total load – with casters

Track capacity up to 100 lbs per ft.

UNEX Flow Cells keep processes and profits flowingBenefits• Increase space utilization by up to 50% — inventory is

organized and stored properly

• Boost production efficiency up to 30% — parts angletoward the picker, making picking easy and fast

• Minimize reaching and improve ergonomics byreducing injury and fatigue

• Create reconfigurable, flexible storage to accommodateline and process changes

• Ensure FIFO inventory rotation — replenishment fromback does not interfere with process

• Keep the factory floor organized — totes and boxes canbe stored in return lanes rather than on the floor

Applications• Lineside storage• Sub assembly stations• Supermarket racks• Modular mobile carts

Features• Flow Cell modular design configured to

meet the needs of your operation• Parts always reachable• Reconfigurable units provide maximum flexibility• Clean sightlines• Heavy gauge steel construction • 7-year warranty• Assemble in under an hour • Adjustable levels on 1” centers• Powder coated finish, RAL: 5004

SpecificationsPosts: Vertical 1.75” square tube with .375” diameter holepunched 1” on center. 3’ – 7’ tall (6” increments standard).Includes foot plate.

Beams: Horizontal 1.75" square tube. 1' – 8' long(6” increments standard). Used for load beams andside beams.

Carton Flow: Span-Track Lane, Span-Track Bed (all duties)

AccessoriesWorkbench: Galvanized steel, 12" and 18" deep

Add-On Pick Tray: 30˚ angle. 12" and 15" deep

Overhead Tool Bar: For tools, lighting and accessories

Casters: 4" diameter. Swivel or rigid (Includes side brake)

Pick Shelves: Galvanized steel, available in tilted and flat,up to 60" deep

Accelerate productivity.Improve Ergonomics.Eliminate waste.Maximize space.Flow Cell workstations are modular, dynamicstorage units designed specifically for a facility’s uniqueoperation. Our durable and flexible storage units supportLean principles by keeping inventory organized andmaximizing pick efficiency.

MODULAR FLOW-THROUGH WORK STATIONS FOR ASSEMBLY AND LINESIDE STORAGE

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 6

Mobile UnitShown with three levels of Span-Track Bed(1.6" Hex Hub) and casters

Stationary UnitShown with three levels of Span-Track Lane(.75" aluminum)

WorkstationShown with three levels of Span-Track Bed(1.6" Hex Hub). Upper levels feature tilted pick trayand lower level features high profile return mountedunder a workbench kit. Taller front posts to supportoverhead tool bar kit.

LinesideShown with three levels of Span-TrackLane (.75" Aluminum) and casters

Solution Examples

MODULAR FLOW-THROUGH WORK STATIONS FOR ASSEMBLY AND LINESIDE STORAGE

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 7

Presentation RackShown with four levels of Span-Track Bed(1.6" Hex Hub) with internal knuckletreatment on lower levels and straightreturn lane above

HD Wheel/SkatewheelShown with three levels of Span-Track Bed HD(1.9" steel) and casters

HD Roller/Battery RackShown with three levels of Span-Track Lane HD(1.38" steel) and casters

Single Lane LaybackShown with three levels of High ProfileSpan-Track Lane (.75" aluminum)

MODULAR FLOW-THROUGH WORK STATIONS FOR ASSEMBLY AND LINESIDE STORAGE

Solution Examples

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 8

Single Lane Cell FlushNarrow cell — shown with Span-Track Bed(1.6" Hex Hub) and casters

Pick Tray SteelShown with four levels of solidgalvanized steel pick shelvesand casters

Pick Tray WireShown with four levels of galvanizedwire pick shelves and casters

Single Lane KnuckledShown with three levels of High ProfileSpan-Track Lane (.75" aluminum) withoptional knuckle treatment and casters

MODULAR FLOW-THROUGH WORK STATIONS FOR ASSEMBLY AND LINESIDE STORAGE

Solution Examples

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 9

PostsPunched 1" o.c. / available in 3 – 7 ft.

BeamsHorizontal, front, back and side beamsare interchangeable. Available 1 – 8 ft.

Welded Foot Plate4" casters optional (rigid or swivel)

Carton FlowSpan-Track Lane, Span-Track Bed.Different track models can be intermixedin a single cell.

WorkbenchGalvanized steel workbench.Available in 12" or 18" deep.

Add-On TrayPresents product to the picker at 30˚to maximize pickability. Available in 12" or 15" deep.

Overhead Tool BarRoll formed strut channel. Attach tools,lighting and accessories*.

* Tools, lighting and accessories supplied by others.

Span-Track ModelsUNEX offers a variety of models to suit any capacity or container type.

Span-Track Lane(0.75 aluminum)

Span-Track Lane HD(1.38 steel)

Span-Track Bed(1.6" Hex Hub)

Span-Track Bed HD(1.9" steel)

11

2

3

4

5

6

7

2

3

4

5

6

7

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

Mix & Match to build your own Flow Cell

MODULAR FLOW-THROUGH WORK STATIONS FOR ASSEMBLY AND LINESIDE STORAGE

unex.com 10

See a configuration you like?Contact UNEX to request a quote now:

Request a Quote

More Storage, More SpaceUNEX flow racks clear the path for growth andefficiency at a thriving automobile plant in Canada.

At the Toyotetsu plant in Simcoe, Ontario, workers stamp themetal frame parts for cars such as the RAV4, Corolla and Lexus.

“Our business is projected to grow considerably in the next 2 years,”says Andy Elkin, Production Control Manager. “We’re anticipating atwo-fold increase in the number of parts Toyota wants us to buildand volume increases for certain models, and that means we need touse our space as efficiently as possible.”

A Peek inside the PlantAt Toyotetsu, components are stored in plastic boxes or hand totes,depending on weight and size. Operators drive tuggers down aislesto find and pick parts, place them on carts and deliver them to thewelding area.

In August 2011, Andy and his team recognized that Toyota’sprojected growth would result in a tight squeeze for the existingtugging zone. Some flow racks had been used since the plantopened in 2007, “but we knew we needed a complete UNEXsystem to save space and increase storage density for components,”says Andy.

“Overall, we gained enough extra storage toaccommodate a 30% increase in business.”

– John Wall, Production Control Assistant Manager, Toyotetsu

Case Study

customer: TOYOTETSU operation: Manufacturing of metal frame parts for Toyota automobiles

goal: Gain space, increase storage density and move components efficientlysolution: Flow Rack systems from UNEX

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 11

Room to GrowAccording to UNEX distributor Brian Pollock, President ofNorthstar Industries, UNEX met with the Toyotetsu teamand custom-designed a flow rack system that eliminated anentire tugging aisle by increasing storage density, doubledthe length of the racks, tightened up spaces between rollerchutes, and integrated the new flow rack system with anexisting one.

John Wall, Production Control Assistant Manager forToyotetsu, says the new flow rack system gave the plant10% more floor space. “Plus, a lot of that racking became abi-level storage area, which means we saved even morespace. Overall, we gained enough extra storage toaccommodate a 30% increase in business.”

The Kaizen Mindset Kaizen, or continuous improvement, is the norm for manyJapanese-owned facilities, and Toyotetsu is no exception.

“The roller racks from UNEX are made of portablematerial, and they are easy for our staff to take apart,reconfigure and put together,” says Andy. “This allows usto make continuous, incremental improvements to ourstorage systems as our business evolves. It also allows usto maintain the Toyota production system: running smallbatch sizes and frequent production lots.”

No Speed Bumps Keeping things moving without interruption on the plantfloor is more important than ever, considering the expectedgrowth ahead. Tugging tractors work on a 30-minute cycle,so team members must get into the pick area, identify theparts they need, get those components on the cart andmove them to the welding area as quickly, safely andaccurately as possible.

“The UNEX racking provides a designated storage area forevery part, and bins are clearly marked with key productcharacteristics,” says Andy. “Team members are able to findwhat they need and keep the job moving forward.”

John adds that when people come into the plant, “theysee a clean, orderly system, and that’s very important forour facility.”

The Right Partner in the Driver’s SeatBrian from Northstar Industries says collaborationbetween his company, UNEX and Toyotetsu was remarkable.“We created prototypes and tested the product flow to makesure the designs worked well and the product wasexcellent,” he says. “This was a situation where teamworkwas strong throughout the entire process.”

Andy agrees. “UNEX took an off-the-shelf system,customized it and made it work with another system.We decided to use our staff to install the flow racks, andUNEX provided the training and stayed in close contactthroughout the installation. This was a good partnership.”

UNEX CASE STUDY: Toyotetsu | Automotive Frame Manufacturer

Flow Rack Benefits for Toyotetsu• Increased storage space• Fewer aisles for tuggers to maneuver• Increased accuracy and speed of pick time• Easy handling and installation of material• Integrated with existing materials

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 12

Line Side Flexibility Takesthe Wheel at AutomotiveProduction FacilityJohnson Controls’ multiple facilities include a 125,000-square-footplant in Suwanee, Georgia, where seats, door panels and otherinterior parts are assembled for the Kia® Sorento.

In the automotive industry, things can change at a moment’s notice.“Customers are always reconfiguring – adding new products andupdating standards. To keep up and stay competitive, our plants mustbe flexible and efficient,” says Todd Emmons, an engineer in theautomotive business unit for Johnson Controls.

Flexibility and efficiency were top of mind in 2009 when JohnsonControls began building a new plant in Suwanee, Georgia. Engineersset out to unveil a state-of-the-art automobile production facility thatcould accommodate the ever-evolving demands of the automobileindustry.

“Our plan was to equip the plant with the most reliable, functional,cost-effective and reusable technology possible,” says Emmons.“The Flow Cell® workstations helped us deliver on that plan.”

Gearing Up for the FutureAt the Georgia plant, employees assemble seats, door panels andother interior parts for the new Kia® Sorento. Nearly 500 cars a day movethrough the facility. “This is a high-volume plant. We’recompleting 55 jobs an hour, and the goal is to step that up to 60 jobsan hour,” says Emmons. “Every minute counts, and every inch ofworkspace does too.”

“This is a high-volume plant.Every minute counts, and everyinch of workspace does too.”– Todd Emmons, Engineer, Automotive

Business Unit, Johnson Controls

customer: JOHNSON CONTROLS operation: A global, diversified company serving the building and automotive industries

goal: Flexible, durable and efficient technology that supports high-volume demandssolution: Flow Cell systems from UNEX

Case Study

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 13

In designing the plant, Emmons worked with John Maicki,president of DR Storage, to identify the line-side assemblytechnology that would best fit current and future productionneeds. “The Johnson Controls team had very specificrequirements. They wanted something durable, ergonomi-cally sound and capable of accommodating the variousproduct sizes on the production line,” says Maicki. “Most im-portant,they needed an assembly line product that could be moved,adjusted and reused as production demands changed.”

Exploring the OptionsIn the past, tubular pipe structures had been used onassembly lines in some plants, but Emmons and Maickiagreed they would not be effective solutions for the Georgiaplant. “Tube and joint structures are highly customized anddifficult to move from station to station. So, if the materialschange on the assembly line, you have to order completelynew racks andinstall them. This takes time and money,” says Maicki.

A better solution came from UNEX. “We did a thoroughanalysis of the line-side racks available, got quotes fromseveral vendors and had prototypes developed. Our decisionwas based on what was best in terms of reliability,cost-effectiveness, functionality and reusability. Flow Cellwas the obvious choice,” says Emmons.

Efficiency Takes a Front SeatEmmons says that Flow Cell units offer huge benefits for thehigh-volume plant, including:

• Efficient use of space. “We only have 84 inches of pickspace per workstation. The Flow Cells are built in sucha way that we never waste an inch of space. And Unex’sFlow Bed carton flow accommodates a variety a varietyof materials, whether we are working with seats, doorhandles, power controls, air bags and the manydifferent types of brackets and buttons. ”

• Uninterrupted work flow. “Our Georgia plant is ajust-in-time operation. We have to keep things movingwithout interruption, so that we can deliver productexactly when the nearby Kia facility is ready for it.The Flow Cells are configured in such a way thatproductivity remains high. And if we need toreconfigure the carton flow beds, it’s simple to do.In fact, reconfiguring the Flow Cells is three times fasterthan reconfiguring other types of products.”

• Reusability. “This is the biggest benefit. Soon, we’ll beadding new car parts to the line for other types ofvehicles. We can simply pick up the Flow Cells, movethem to another place in the plant or another newlocation entirely, and reconfigure them. There’s no needto buy new racks.”

• Added value. “The more efficient we can make theprocess, the more value we can offer customers, andthat translates into more products for our operations.”

Navigating Growth with the Right PartnerBoth Emmons and Maicki have a long history with UNEXsolutions. “We’ve used other UNEX solutions in our plants,and UNEX was the clear choice for the Georgia facility,” saysEmmons. “Overall, we’ve ordered 41 Flow Cells and used theUNEX instructions to assemble them in less than a half anhour each.”

Maicki adds, “I first recommended Flow Cell to a customerin 2003, and I’ve been recommending it ever since. The FlowCells have broad application and always provide the qualityand durability customers need on the line. It’s always asuccess story with UNEX.”

UNEX CASE STUDY: Johnson Controls | Automotive Parts Production

“It’s always a successstory with UNEX.”– John Maicki, President,

DR StorageUNEX Distributor and systemsconsultant for Johnson Controls

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 14

Modular Flow-Thru Workstations Help This GM SupplierDeliver “Just in Time”… Every Time

Big wheels keep on turning in Shreveport, LA – big 18 wheelers that is –as they make the one mile drive from Android Industries’ new assemblyplant to GM’s sprawling manufacturing complex, delivering completedengine and transmission assemblies for ‘just-in-time’ placement ontoawaiting truck chassis.

According to Mark Geer, Lead Engineer and member of the launchteam for this new facility that went on-line in 2003, the company’scommitment to build in Shreveport was the result of being awardeda GM assembly contract to support the introduction of two new trucklines – the Chevy Colorado and GMC Canyon.

Not a Robot in the House!It may come as a surprise to learn there’s not a robot to be found in the226,000 sq. ft. Android Industries building, or for that matter in any oftheir other facilities.

“We can put 4 days worth of partson the Flow Cell and not have toreplace material.”– Mark Geer, Lead Engineer, Android Industries

customer: ANDROID INDUSTRIESoperation: Engine and transmission assembly plant

goal: Keep assembly lines moving to satisfy “just-in-time” demands at GMsolution: Flow-Cell Modular Flow-Thru Workstations from UNEX

Android Industries, a valued GM supplier since 1989, knows the roadto a successful relationship and what it takes to keep pace with therenowned car and truck builder. At its seventh and newest facility inShreveport LA, it takes top quality outfitting or“engine dressing” of close to a thousand GM engine/transmissionassembliesper day, sequenced and delivered ‘just-in-time’... every time!

Case Study

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 15

UNEX CASE STUDY: Android Industries | Automotive Assembly Plant

But up and down the ‘line’ today in Shreveport, highlyskilled Android Industries technicians are meeting andexceeding critical production targets. And right alongsidesilently assisting them are fully stocked UNEX® Flow Cell®Workstations from which components are quickly and easilypicked and attached to the engine/ transmission assembliesat a steady, seemingly choreographed pace.

In manufacturing operations, UNEX Flow Cell Workstationswith full-width roller Span-Track® are typically used ‘line’ side,as they are at Android Industries, and perform a dual function:maintaining a ready supply of components and making themavailable for easy picking.

“We can put 4 days worth of material on the Flow Cell and not have to replace material,” Geer says.

Also, he explains that Shreveport is the first of their facilitiesto employ UNEX Flow Cell Workstations.

Geer anticipated outfitting the new Shreveport facility withequipment similar to that operating in their other plants. Butwhen it came to workstations, he knew that the ubiquitous“pipe type” structures with plastic wheels was not what hewanted to continue being saddled with. “Bolt boxes don’t godown wheels very well,” he says.“The Span-Track full length rollers sections in the Flow Cell iswhat we needed.” Geer recalls “heaps” of pipes cut to everywhich size stored in other plants in hopes of someday beingsalvaged for reuse. Someday never arrived and the piles ofpipes presented more work than value to Android.

Modular Flow Cell Units - Easy to Moveand Refit“We were doing the initial start-up and wanted to put asystem in place with the greatest flexibility for change,” Geercontinues. With employees on the ‘line’ working at variousheights from the plant floor and assembly operations thatcould likely change according to new contracts, workstationshe would purchase had to assemble and disassemble easily,be capable of being reconfigured as needed and be durablefor movement around the plant.

Mark Geer found the workstations that met his company’srequirements when Blake DeFatta from Nelson EquipmentCompany, UNEX’s Shreveport distributor, recommended FlowCell Modular Workstations. He found ease of assembly anddisassembly, durability, mobility and flexibility.

According to Bill Edgy, UNEX Manufacturing’s SouthernRegional Manager, “99% of the time assembly is done by theend user,” which is why Flow Cells were designed for quick,easy assembly. The rugged construction assures the cellswithstand the heavy duty, high volume pace of themanufacturing process and perform well beyond the SevenYear Platinum Warranty.

Nelson Equipment Company’s president and owner MarkNelson indicates that his company has supplied a largeamount of equipment to Android and as a result they havea good understanding of their operation.

“They counted on us to bring in a quality product thatwould help speed along their operations and Flow Cell wasthe appropriate choice,” he says. UNEX Flow Cell ModularWorkstations are comprised of standard “Mix & Match”components that form an efficient, ergonomic station whereparts and product are always ready and reachable. Theyinclude vertical posts, horizontal beams, and Span-Trackfull-width roller tracks that provide the flow from load pointto pick point – even for hard to handle totes. Span-Track iseasy to add and reposition within the Flow Cell.

“It does what it’s supposed to do and doesn’t take up alot of floor space,” says Geer. “You spec it for what you need.

We ordered 22 Flow Cell units and they all wenttogether in one day. It probably took about 30 minutesto set up each Flow Cell and everybody that assembled

the units out here were production line employees.”

Pick Smarter. Pick Better. Pick UNEX. • 800.695.SPAN (7726)

unex.com 16