Smart Industry 4.0 process improvement systems from Werma that simply work
29 August 2018
Read how cable manufacturer Auto-Kabel controls Kanban stock replenishment with StockSAVER. StockSAVER is a maintenance-free system which is easy to retrofit to any FIFO flow rack. Sensors fitted to the flow racks ensure complete transparency of stock levels and safeguard against material running out or misplaced stock.
The global automotive supplier Auto-Kabel manufactures cable and lead sets for power supply applications. The friction welding machines deployed in the process must always have an adequate supply of material to work on without excessive safety stocks. Flow racks are located next to the manufacturing machines and provide the operators with the components such as cable shoes and eyelets. The flow racks contain more than 90 stock locations which are each filled with three bins with each bin containing approximately 400 parts.
The challenge – reduce downtime
The Industrial Engineering department at Auto-Kabel is responsible for the optimisation of manufacturing processes on all sites. Staff immediately recognised that there was great potential to make an improvement in the kitting of parts for the welding machines where there had always been bottlenecks. “The high throughput of components like cable shoes and eyelets often led to shortages and idle time because replenishment was inadequate. We wanted to put a stop to this but without excessive cost, nor did we want to increase the amount of safety stock being held”.
Easy to install, simple to operate
StockSAVER is a maintenance-free system which is easy to retrofit to any FIFO flow rack. Sensors fitted to the flow racks ensure complete transparency of stock levels and safeguard against material running out or misplaced stock.
The system works very simply: sensors monitor the number of bins held on the FIFO flow racks. The number and movement of bins is then sent to the “SmartBOX” and from there on wirelessly to the StockSAVER software and displayed as a digital copy of the actual stock held on the flow racks. The system solves many traditional Kanban problems such as lost or damaged Kanban cards or human error in replacing bins on the racks and frees up space on the factory floor for other activities and, last but not least, improves cash-flow. The automatic stock replenishment system reduces the margin for human-error and can reduce the levels of safety stock held considerably.
Great benefits immediately after the trial
After the trial, during which 3 flow racks with 90 stock locations were fitted with the system, significant improvements were seen. The target of reducing machine idle time was easily met. “Immediately after setting the system up we were able to reduce idle time and safety stocks. The project paid for itself within 6 weeks!”
If you would like to learn more about StockSAVER, or arrange for a free demonstration of the system on-site please contact:
uksales@werma.co.uk
tel: 01536 486930
www.werma.co.uk
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