Project of the Month
"Enhancing Efficiency in Mass Timber Manufacturing"
Lean Integration for Glulam Beam Assembly
BACKGROUND
Glulam beam production involves large components and complex workflows. Lean principles - like waste reduction, flow optimization, and standardization - are essential for improving efficiency and quality.
Key Lean Concepts:
- Standardized Work Cells for all beam sizes
- One-Piece Flow & Pull System to reduce WIP
- Minimized Handling via mobile teams
- Visual Management for clear process visibility
INITIAL SITUATION
Challenges in the assembly process:
- Delays from missing parts
- Rework causing bottlenecks
- Excessive WIP due to unstructured flow
- Inconsistent workstation setups
OBJECTIVES
- Cut material flow delays by 30%
- Use uniform work cells for all beam sizes
- Introduce buffer zones to separate kits and QC issues
- Reduce waste and downtime by 20%
IMPLEMENTATION
- Lean integration: rotating teams, balanced stations, pull system
- Workplace optimization: uniform cells, reduced setup times
- Buffer zones: separation of complete/incomplete kits, QC hold, recycling
- Defined work areas: structured assembly zones with quality guidelines
CUSTOMER BENEFITS
- Faster lead times
- Higher quality, less rework
- Greater production flexibility
- Lower costs through efficient resource use
- Smoother logistics and just-in-time delivery
Through close collaboration with the customer, the assembly process was successfully streamlined. The implementation of lean principles led to greater efficiency, improved quality, and more reliable delivery timelines.