New Assembly Line for Point Machine H715

In January 2022, we opened our new assembly line for point machine H715. This project was the pilot for implementation based on Lean Six Sigma improvement methods.
By Reinhold Büker

HANNING & KAHL has been successfully practising Lean improvement methods for years with the objective of reducing waste and extra-processing, and thus increasing efficiency. Six Sigma is a zero defects strategy which covers entire processes. Lean methods and the Six Sigma combined in Lean Six Sigma form the ideal strategy for improvement.
The pilot project for point machine H715 began with a team of staff from production, construction, logistics and operations scheduling establishing the actual situation. Weak points in the process sequences were analysed, and significant influence factors were depicted in quantifiable manner.

The team then devised possible solutions and, using the new VisTable software, a new workstation layout was created in 3D, taking the logistics value chain into account. 

The process sequences could thus be simulated, and possible weak points corrected immediately. After all team members were convinced of the increased efficiency to be expected, implementation was started and successfully commissioned in January 2022 
 
We no longer assemble on rigid workbenches with fully commissioned order batch sizes. Sub-assembly pre-assembly is also no longer necessary.

95 percent of all individual parts required are now provided in a 2-bin Kanban principle directly at the assembly line. Assembly now follows the one-piece flow principle which eliminates searching.

This means that up to three colleagues assemble one complete point machine H715. The assembly platform is an assembly table designed for the size of the finished product, and it has all the parts required on it. Unlike with a space-consuming roller conveyor, here not only the workpiece moves along in front of the supply shelves, but the assembling staff move along the supply line, finding the parts needed at their side.

This has significantly increased assembly efficiency and considerably improved the transparency of material supply and output quality. Staff also greatly appreciate the new assembly line and the new process sequences. We are currently implementing material supply for the Kanban concept and when finished, the line will be continuously operated.

Following the major success of the pilot project, Lean Six Sigma methods are to be applied in other assembly areas, too, in our quest for further improved process output quality.