motion control - Industrial Technology Magazine

The new Lean philosophy has eliminated a lotof wasted time and unnecessary paperwork fromthe process. As an order is received it is postedto the computer system which is then updated onthe shop floor every ten seconds. Every componentthat is required to make the cylinders is on Kanbanwhich is a signalling system used to “pull” workthrough the system as opposed to the “push”system used in MRP. When components in anyof the Kanbans reach their reorder levels then theteam leader has direct access to the supplier andcan arrange for more material to be delivered.The team leaders routinely check thecomputer for new orders. They also check thecustomers required delivery to ensure that all of thecomponents that are needed are in stock. Providingthe order can be completed it is acknowledgedand entered to the production plan. If any of thenecessary components are not available then theorder is rejected, however this currently representsless than .002% of all orders. If a requested deliverycannot be made due to stock shortages then thecustomer is immediately contacted with an expecteddelivery date.Dependant on requested delivery, ordersare moved from the production plan into work inprogress (WIP). This generates a demand signalthat immediately propagates through the entirechain, pulling all the necessary componentsthrough. The number of jobs in WIP at any one timeis tightly controlled and once there, they should becomplete within one hour.Four hour deliveryThe changes that have been made tothe manufacturing processes enable ASCONUMATICS to offer cylinders, made to orderand ready for delivery within four hours of orderreceipt. Making to order enables a vast range ofcylinders to be produced to specification insteadof a customer having to accept a cylinder froma limited range held in stock. Providing contactis made before 1:00 pm, ASCO NUMATICS canhave a cylinder ready to ship that day. Cylinderscan be despatched by taxi, overnight courier, orthe buyer can collect.The same Lean manufacturing techniquesemployed on the cylinder line have also beenadopted for the manufacture of solenoid valvesand solenoid coils. The company manufacturesthe complete coil from winding through toassembly, encapsulation and testing. AdoptingLean techniques has seen the cost of productiondrop significantly and as a result, production fromother European plants has been transferred toSkelmersdale.Originally manufacturing for the UK marketonly, ASCO NUMATICS output was 100,000 coilsper annum in 2002; now it manufactures 1.2 Million.This is expected to increase to more than 2 Million.“Key to the success of our plant is ourworkforce,” said Jean Christophe Serkumanian,Managing Director of ASCO NUMATICS in theUK. “Responding to these changes, our workershave risen to the challenge, taken ownership anddriven these changes through. We are now muchmore responsiveto customer needsand in turn areimpacting on thelocal economy bysecuring continualemployment.”Jean ChristopheSerkumanian,Managing Director ofASCO NUMATICS inthe UKWhen your factory has stopped.Every second counts.With an extensive range of pneumatic cylinders, made toorder within four hours, ASCO NUMATICS is able to get mostplants running within a few hours of a breakdown.By manufacturing to order we are able to supply exactly whatyou need, and not compromise on plant efficiency or safety.To challenge us call 01695 713600.www.asconumatics.co.uk4 hourServiceMore details: Write in 350 on the free information card 35