LANTECH COMPANY PRESENTATION Configure me [Compatibility

Is ”Flow Assembly” mogelijk bij
klant specifieke geconfigureerde
machines?
JA dit is heel goed mogelijk
Flow Production
Frank Wijers Site Manager
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Lantech playing field:
LANTECH IN A NUTSHELL
Palletizing
Louisville, USA
Stretch wrapping
Inventor of stretch wrapping
with > 70.000 machine placements, > 150 patents
Since 2001 present in Europe via Rembrandt Packaging
Global partnerships with top 10 multinationals
Serving small and midsize enterprises in production and
logistics industries with a network of 200 partners
Case/Tray sealing
Case/Tray packing
Case/Tray erecting
USA
LOUISVILLE (KY)
EUROPE
CUIJK (NL)
Cuijk, NL
The Evolution
1972
We continuously improve our
products and develop new
machines
2001
2003
1980
2004
2007
2009
2014
Global sales & service
1985
Worldwide wide installed base > 70,000
machines
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OUR CORE PRODUCT GROUPS
Case Handling
Case Erectors
Case Sealers
Case Packers – Top Load and Side Load
Tray Handling
Tray Erectors
Lid Former & Lid Applicators
Stacking Edge Closers
Tray Packers
Stretch Wrapping
Semi Automatic Turntable and Overhead Rotary Wrappers
Simple Automation Turntable and Straddle Wrappers
Fully Automatic Turntable, Straddle & Ring wrappers
Lantech’ s journey
From “One-off” to batch to flow
Growing business : More machines in the assembly simultaneously
be more effective?
3
Highly engineered solutions, money is not
the bottleneck (Niche)
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Custom specific, but not for all cost
1
Price is main driver to decide
Configure to Order instead of Design to Order
Re-use of knowledge: less engineering time, less mistakes and errors.
Accurate cost and therefore predictable projects.
Reduce Lead-times.
…
How can we
Batching: We created a Pre Assembly Center:
Repeat the same kind of work
Assemble the same modules in advance
Reduce assembly time
What happened:
Always the wrong module prepared
High assembled stock levels
Customers do need just a bit different
High level of rework in the end assembly
Always need for specific skill due to batched work:
Pre assembly operators
Final assembly operators
Final test operators
Installations at the same time
Machines all over the place. But nothing to ship…….
This was before knowing anything about flow
From One-off to batch to FLOW?
Prejudices at Lantech
All machines/ products are different, therefor it is not possible with our
machines/ products
Partly true: You do need a form of similar work.
Similar work is something else than the same machines/ products
Cable Trays
Pneumatics
Find the best way to build the different machines from a family from start to end:
What is the sequence? What is the total time needed. (=Cycle time)
Define the main pieces of work per machine type: What is similar (Does not
need to be the same!!!)
Split the work in pieces that are matching the takt time.
Machine
Frame
Lantech Approach
Calculate takt time Case erectors.
Control
Cabinet
Handling
module
We cannot predict when and what machine orders do come in
Partly true: You do need some flow + some mix
We do create sales budgets…… so there is an average
History tells a lot
Guarding
Example
120 Hours mechanical assembly time.
Available time: 36 hours.
Demand 3 machines per week
takt time is 36 /3 =12 hours.
Divide 120 hours of total time in blocks of 12 hours = 10 work pieces.
Do this for the typical machine configurations from a machine family.
Lay-out the work elements and start.
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Learnings & FAQ
Learnings: Do and Don’t
Some machine types do need more time? (At Lantech ratio max 2)
Schedule the Mix
level the average work load.
Have capacity available to add people to the process.
Have the operators involved
Be open to see the bottle necks
Improve continuously
Walk away: The flow will need
support
Forget to train people. What is the
job per station
Ensure to support operator
Try to solve in theory: Learn by
doing
Implement clear “Q pass” steps at
hand over points
Focus on the exceptions (80-20
rule)
Use Time recording to find
bottlenecks and hard en tedious
work
Use time as a mean to push
people to work harder
Ignore issues and work around: It
is a sliding slope
Lantech Mixed Model CE Line
What to do with the people that are not needed?
There are always things to improve: Make live easier.
How to handle the variation in time per work area?
Isolate the “strange, rare work” from the flow line.
What to do with customization?
Ask yourselves; does this really create different work?
Not all customization does impact the work:
Examples:
• Longer module, but same BOM structure.
• Different brand photo-eyes.
Isolate the “customization”.
• Pre assemble, or assemble in a later stage.
How is Configure to Order related?
It really helps because of the already existing high similarity.
Lantech Mixed Model CE Line
Case erectors
Variation in models:
In different sizes:
Case size max 500x325
Case size max 1000x600
Start of line: Main frame
Final station of the line
Middle of the line
Work station
C300/C400 STD Tape
Variation in execution
-Speed 8 CPM (pneumatic drives)
-Speed 30 CPM (servo drives)
-Tape and/or hotmelt
-Stainless steel
C1000 Hotmelt
Optional like:
-Extended blank magazine
C3000 Tape + Hotmelt
-Vacuum by pump or by venturi
-Additional diagnostics (eg tape almost empty)
-On wheels
………..
Blank magazine from a different
flow assembly line
Manual versus auto
adjustable
Final test area
Challenges of today
Design changes
A design change does not stop at the BOM/ Drawing.
A change does have impact to the assembly environment.
A change can have impact on the assembly time
re-balance!!
Increase capacity is not just adding people
People in a flow assembly line are trained for specific tasks in a more
dedicated area.
Training programs are a must.
The importance of support
When there are issues in a FLOW production line, the entire line stops.
A missing parts or a design mistake does have a very big impact on multiple
machines.
Supporting departments like Engineering/ Procurement/ Logistics do need
to understand and handle quickly.
Being on time is not normal in our industry: How to handle delays…
No test materials, factory not ready, …..
Project managers do go for save schedules added time, stops the flow.
Some overall results
From batch to Flow in Case erectors.
Created a flow assembly line for the sealers.
Created a flow assembly line for the tray erectors.
Split highly engineered machines in blocks Flow.
Flow start to appear in all processes.
On Time Delivery 99.5%.
+130%
Some figures.
Year 2007
+60%
2011
2012
2008
2009
2010
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
Tact CE(/wk)
xx
xx
x
x
x
x
x
x
Tact CS (/wk)
Xxx
xxx
xxx
xxx
+100%
xxxx
xx
Takt TE (/month)
xx
xx
xx
xx
xx
xx
Xxx
xxx
xxx
xxx
xxx
xxx
xxx
Machine OE (MEuro)
People (FTE)
Qty Mach total
2013
2014
2015*
xx
xx
x
xx
Xx
xxx
X
X
X
x
x
X
x
X
X
xxx
xxx
* extrapolated September - Year end
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Questions?
Thanks
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