Flexpipe Kaizen Tool

One of the eight types of waste identified in lean methodology, motion waste is any movement during a work process that does not add value to the customer. This includes actions such as walking, bending, lifting, and reaching that slow down the process and make the task more difficult for the operator.

As Shoplogix’s Martin Boersema explains in this video, motion waste tends to be the most common type of waste in a work cell—but it is relatively easy to correct through continuous improvement initiatives such as kaizen events.

How to identify motion waste
To identify motion waste, observe the work process and take note of any movement that seems to be slowing things down. Maybe the operator has to walk across the shop to read a set of instructions, or they spend several seconds fiddling with a part.

[caption id="attachment_26243" align="alignnone" width="2560"] One of the eight types of waste identified in lean methodology, motion waste is any movement during a work process that does not add value to the customer.[/caption]

Ask questions to find out why these extra movements are taking place. Once you determine the cause of the waste, you’ll be able to come up with solutions.It’s helpful to conduct a time study on the work process to find out exactly how long it takes to execute each step. If there is fluctuation in the time it takes to perform a particular task—maybe sometimes it takes 30 seconds, but other times it takes 60 seconds—motion waste might be the culprit.
Common types of motion waste
Types of motion waste vary depending on the work process. In an injection molding cell, for example, the operator may have trouble keeping up with the machine’s production cycle if they have to walk several feet away from their workstation to retrieve the parts they need.

Or perhaps they can still keep pace with the machine, but the seconds they spend walking could be better spent on a task that adds value, such as performing an inspection.

In an assembly cell, where the work is performed manually, the efficiency of the process depends on how easily the operator can carry out each step. Small issues might slow down the work—maybe they have to fiddle with a part to get it to fit inside its nest, or they have to rotate their body to reach the tools they need.

If the workspace isn’t organized efficiently, employees will wind up moving around as they search for missing parts, tools, or information.

[caption id="attachment_26252" align="alignnone" width="1920"] If the workspace isn’t organized efficiently, employees will wind up moving around as they search for missing parts, tools, or information.[/caption]
How to reduce motion waste
In many cases, motion waste can be reduced by making necessary equipment more accessible to the operator. This might mean replacing a large cabinet with a tool cart that can be wheeled closer to the operator’s workstation, or perhaps substituting a large bin with several smaller bins so that the operator doesn’t have to reach far inside to retrieve the part they need.

To eliminate motion waste related to searching, it’s important to ensure that all equipment is stored in the right place and properly labeled; there should also be an effective communication system in place. Visual management is a lean technique that can help with this.

Other types of bottlenecks will require their own targeted solution. If an operator is struggling to fit a part inside its nest, the nest might need to be redesigned for a better fit. If an operator has to manually insert a part at one end of a machine and then eject it at the other end, it might be worth examining whether one of those tasks can be automated.

[caption id="attachment_26258" align="alignnone" width="815"] In many cases, motion waste can be reduced by making necessary equipment more accessible to the operator.[/caption]
How motion waste impacts employees
Employees who have to make a lot of unnecessary movements while performing a task often experience fatigue, sore muscles, and sometimes even injury. Some people may not realize the extent to which excessive movement affects them; they might think that a second or two of bending or lifting isn’t a big deal.

However, when solutions are implemented to reduce motion waste, most employees notice that they are less tired, especially at the end of the work week.

[caption id="attachment_26249" align="alignnone" width="815"] To eliminate motion waste related to searching, it’s important to ensure that all equipment is stored in the right place and properly labeled[/caption]

Part of continuous improvement is training employees to spot motion waste and working together to find the right solutions, but it’s also essential to educate managers about the problem.

Ultimately, they will be the ones implementing the improvements that will make a significant difference in their employees’ quality of life.

About Shoplogix
With its industry-leading smart factory platform, Shoplogix helps manufacturers reduce operating costs and maximize profitability by unlocking hidden production performance improvements. Headquartered in Oakville, Ontario, the company has an international presence, with offices around the globe.

Kaizen is a Japanese word meaning “continuous improvement,” and it refers to the incremental steps taken to create a more efficient, optimized workplace. As the concept of kaizen has gained popularity in North America, many companies have started holding kaizen events to improve specific areas or processes, as Shoplogix’s Martin Boersema explains in this video.

What is a kaizen event?

The goal of a kaizen event is to make improvements to a particular area or process within a business. In the manufacturing sector, this involves a kaizen facilitator meeting with operators and supervisors, usually over a few days. The aim is to analyze the current process and identify potential improvements.

How to lead a successful kaizen event

If you’re facilitating a kaizen event, here are a few things to keep in mind.

Don’t try to solve the problem yourself.
To understand the problem and identify the right solutions, speak with the people most familiar with the process you’re analyzing: the operators. Ask them what problems they deal with on the job every day. Their answers will help you determine the appropriate improvements.
Choose your team carefully.
Most participants in your kaizen event should be directly involved in the process you’re reviewing. Include the operators, but also the supervisor, as they will be the one overseeing any changes you decide to make. It’s also a good idea to invite an employee who is not involved in the process—they can often provide a fresh perspective on the problem at hand.
Understand the company’s goals.
As leader, you’re responsible for ensuring that any proposed changes are in line with the company’s strategic objectives. This means finding a balance between optimization and what the company needs. For instance, you might find a way for an assembly line to produce 300 parts per hour, but if only 200 parts per hour are required, this “improvement” may not be necessary.

How to handle reluctant participants
Some employees may be reluctant to participate in a kaizen event. They may feel that their work process is fine the way it is. Or, they may have reported problems with their work process in the past and feel frustrated that no one listened to them. They may think the kaizen event isn’t going to solve anything.

The best way to deal with reluctant employees is to talk with them on the shop floor. Ask them to walk you through their work process and what problems they have with it. If there’s room for improvement, it will most likely come to light during your discussion.

The key is to have these conversations at the worksite, not in a classroom. The kaizen event participants will be able to show you the challenges they struggle with, and you’ll get a more complete picture of the situation.
A common pitfall of kaizen events

Let’s say you lead a successful kaizen event that yields a list of useful improvements to be made and a plan for how to implement them. But then, weeks later, you discover that the work process has reverted to its former inefficient state. Why? It turns out that the manager wasn’t on board with the changes.

When leading a kaizen event, you must make sure the people in charge approve of the proposed changes. They will be the ones deciding whether to follow through on your recommendations, so be sure to take the time to explain how the changes will benefit them, their team, and the company as a whole.
The impact of a successful kaizen event
The improvements that come out of a kaizen event will ultimately lead to a better return on investment for the company. Small improvements (5S activities, for example) may not have a major impact on the bottom line in and of themselves, but over time, they add up.

For the employees, however, even small changes tend to have an immediate impact: suddenly, they have a solution to a problem they’ve been struggling with, in some cases for a long time. In this way, kaizen events often lead to happier, more engaged employees.

 
About Shoplogix
With its industry-leading smart factory platform, Shoplogix helps manufacturers reduce operating costs and maximize profitability by unlocking hidden production performance improvements. Headquartered in Oakville, Ontario, the company has an international presence, with offices around the globe.

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WHAT CAN FLEXPIPE DO TO OPTIMIZE YOUR PLANT EFFICIENCY?
Flexpipe Modular industrial pipe racking system can help you with implementing continuous improvement principles. Your team’s creativity can result in a 10% increase in productivity per year. It has been a proven system for more than 50 years now.

See how the modular system can increase production efficiency by 25% in manufacturing processes at Hologic.

Value stream mapping involves creating a detailed visualization of all the steps in your manufacturing process, allowing you to identify problems and potential improvements. It’s one of the fundamental tools of lean management, as TXM’s Normand Sawyer explains in this video.


What is a value stream?
The term “value stream” refers to the series of steps an organization takes between the initial order of raw materials and the delivery of the finished product to the customer. This includes both value-added actions (steps that contribute to the product’s value for the customer) and non-value-added actions (steps that bring no value to the customer, such as moving equipment or waiting between tasks).
What is a value stream map?
A value stream map is a detailed flow chart representing every step in your manufacturing process. It shows you how materials and information progress through your workspace and indicates all inventory points and processing and lead times, helping you spot bottlenecks and wasteful activities.

Value stream mapping actually entails creating two maps: one of your value stream as it currently operates, and another representing your ideal future process, with current problems solved.

Creating a detailed map of your workflow’s current state is a crucial first step. To find effective solutions, you’ll need a thorough understanding of your existing process.
Why create a value stream map?
The essential function of a value stream map is to help you visualize the following aspects of your production process:

Flow of information: How information is communicated throughout the workspace
Flow of materials: How parts progress through the workspace
The big picture: How individual processes fit together as a whole

Representing these things visually makes it easier to spot strengths and weaknesses across your entire workflow—not just in specific areas. For instance, you might notice that operators spend the first five minutes of their shift awaiting instructions from a supervisor. You can then figure out how to eliminate that wait time, such as by posting instructions at workstations. Or, you might see that parts tend to pile up at one workstation, causing delays further down the production chain. You can then come up with a strategy to eliminate the bottleneck.



If you’re planning to adopt the principles of continuous improvement in your workplace, it’s best to start with value stream mapping. You’ll find out exactly what needs to be fixed and be better equipped to choose the right solutions.
How do you create a value stream map?
First, choose which process you wish to map. If you manufacture several types of products, they likely go through different processes and will each require their own map.

Once you’ve decided which value stream to focus on, put together a team. Value stream mapping is not a solo endeavour—to get an accurate picture of your current workflow, you’ll need to consult the people who are performing the tasks.



Next, begin gathering data. To ensure accuracy, it’s essential to observe operators at work and ask questions rather than relying on reports from managers. The goal is to get realistic information about each step, such as turnaround time, quality level, and changeover time, as well as details about any setbacks the operators face. Let people know your goal is to find ways to improve the overall workflow, not to criticize their performance; they’ll be more honest about the challenges they face and may volunteer useful information.

Now it’s time to map out your data on a whiteboard. The finished value stream map should resemble a flow chart, with detailed notes about every step of the workflow. Analyze your map and identify problems that need to be addressed.

Consider what changes could be made to solve these issues. You can start by asking yourself what the customer needs, then work backwards: what should the finished product look like? What steps are involved in creating that product? Can any steps be combined or eliminated? The answers to these questions will allow you to map your ideal workflow and determine how to achieve it.



Above all, remember that value stream mapping is a diagnostic tool, enabling you to assess the health of your production chain as a whole. Once you’ve completed a value stream map, you can implement specific lean manufacturing techniques, such as an Andon system or visual management, to create a more robust workflow.

TXM - Who they are?
TXM is a leading international lean consulting company with projects in more than 15 countries. Established in 2004, the company’s scope has since expanded beyond the manufacturing industry, with a team of diverse lean professionals lending their expertise to the resources, services, agriculture, supply chain, and distribution sectors.

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WHAT CAN FLEXPIPE DO TO OPTIMIZE YOUR PLANT EFFICIENCY?
Flexpipe Modular industrial pipe racking system can help you with implementing continuous improvement principles. Your team’s creativity can result in a 10% increase in productivity per year. It has been a proven system for more than 50 years now.

See how the modular system improve operational efficiency while saving time in manufacturing processes at Waterax.

One of the principal tools of lean manufacturing, visual management is used to communicate information about your operations in a way that is easy to understand at a glance, helping to facilitate safer and more effective workflows as well as saving time and reducing waste.

In this video, Leslie Pickering, co-owner of consulting firm Quadrant5, explains some of the key concepts of visual management and how they can help you make your workspace more efficient.

Communicate with visual indicators
Visual indicators, such as colours and floor markings, are one of the simplest ways to convey information in your workplace, allowing employees to locate equipment or determine production status with just a glance.

For instance, you might mark the upper end of a floor-to-ceiling pole with red paint to signal the location of a fire extinguisher. Or, you might install different colored anodized washers behind lubrication points to indicate different types of lubricants or different lubrication schedules (for example, red for weekly lubrication and yellow for monthly lubrication). Colors can also be assigned to machines, parts bins, and their associated tools so that there is never any doubt as to which tool should be used for a given machine.

Floor markings, meanwhile, can be used to communicate workflow and define the purpose of particular areas of your space, such as loading and unloading zones.

Optimize efficiency with visual aids
The idea behind visual aids is to lay out all the tools an employee needs to perform a particular task, and nothing else. They can be configured in various ways depending on the operator’s needs.

Tool boards—either a wall or a mobile board with a spot for every tool, designated by colour, shape, and label—are a great example of a visual aid. Unlike with toolboxes, a missing tool can be spotted immediately, meaning the operator can easily determine whether they have everything they need before beginning their task. A well-designed tool board will have plenty of space between tools so that the operator can easily pick them up.

 
Boost productivity by reconfiguring visual spaces

It’s a good idea to look at individual workstations, storage spaces, and equipment and assess how their layout might be improved; this can save operators significant time and effort.

Workstations should be tailored to meet the needs of the people who use them every day, and with the expectation that processes will change, ensuring maximum usefulness and adaptability.

A disorganized shelving rack, for example, might benefit from the addition of a pipe-and-joint system to keep materials organized and in place, thereby reducing the time the operator spends looking for a given material.

Consider also the differences between a heavy steel cart versus a modular cart with a pipe-and-joint system: when transporting materials, the modular model is not only lighter, but can also be adapted to accommodate different shapes.

These examples highlight just a few of the ways visual management can improve process efficiency. What’s more, these techniques are in many cases cost-effective and relatively simple to implement.

Le Chaînon has seen its reception capacity reduced to 50% due to the pandemic linked to Covid-19. A donation of divider panels made it possible to continue to welcome and support women in difficulty in a safe environment for all.

Le Chaînon is a Montreal-based organization that has been helping women in transition since 1932. In addition to its helpline and support services available at all times, it offers short and long-term accommodation to more than 500 women annually.

One of its most-used services is emergency accommodation, which houses 12 women every day. They spend the night in a secure dormitory, can eat supper and breakfast, and receive many services, such as healthcare and clothing care.

Unfortunately, with the arrival of the COVID-19 pandemic, the shelter had to reduce its lodging capacity by almost 50%. In fact, due to the physical distancing measures decreed by Public Health, only seven women could sleep there.

Since the occupancy rate was 100% before the health crisis, the organization did not want to penalize those needing its services by accommodating fewer women.

Helping Le Chaînon pursue its mission
Le Chaînon’s management came up with the idea of installing protective panels. After doing some research, they learned that Flexpipe made sneeze guards to limit the spread of the coronavirus. Excited by this great project, we donated several panels to them and made the trip to Montreal to come and install them.

 
In the picture, Julia Sourbé, Patrice Mongeau, Richard Forgues, Katia Poulin and part of the Flexpipe team

Flexpipe sneeze guards are made with steel tubing and connectors that form the frame of the structure. Mika fabric, which helps block droplets, forms the wall and is attached to the frame with self-locking tie wraps.

There are several models, some of which are installed directly on the floor, and others on counters or furniture. Regardless of the model, assembly time is generally only 15 to 20 minutes per panel.

Panel installation
At Le Chaînon, we installed protective panels in the dormitory, as well as in the common dining room. In the first case, we installed partition walls between each of the 12 beds, starting at the height of the pillows. 

Since the fabric used for the panels is transparent, the organization’s officials can easily see each of their residents and chat with them, while respecting the hygiene rules related to COVID-19. Solid panels, for example those made of plywood, would not have provided the same advantage.

In the dining room, we installed smaller sneeze guards the middle of each of the tables. Thus, the organization can serve as many meals as it wishes, without having to reduce its capacity. Additionally, women can sit across from each other to eat and chat, which helps to overcome isolation.

Mika fabrics not only improve communication, they also increase the lifespan of the panels. If the fabric ever got damaged, the organization would not need to get a new structure, it would only need to replace the damaged fabric, a process that only takes a few minutes. Tubes and connectors are strong and built to last for years.

Multi-purpose equipment
Once the pandemic is over, Le Chaînon can easily use the protective panels to meet new needs. Like the other Flexpipe products, these are fully modular and easily convert into a shelf or support for an electronic tablet or laptop.

In this picture, Sonia Côté, president and general manager at Le Chaînon, surrounded by Eric Collard and Sylvain Lejour of tinktube and Flexpipe.

We are very happy to have helped this wonderful community organization continue to operate during this time of uncertainty. Thanks to our sneeze guards and partition walls, Le Chaînon was able to install sneeze guard separator panels in the dormitory, in the cafeteria and in the Le Chaînon store.

If you’re like most manufacturers, you probably still rely primarily on manual operations, which are prone to problems that can affect the entire assembly line. A great way to quickly pinpoint issues at manually operated workstations, improve response time, and reduce downtime is through an Andon system.

What exactly is an Andon? The term Andon is the Japanese word for paper lanterns. The Andon system, a lean manufacturing process, was originally pioneered by Toyota as a signal system using lights to alert a manager to the occurrence and location of a problem on the assembly line.

In this informative video, Bob Wilson, an Andon and lean manufacturing consultant, explains the main features of the wireless Andon system and how it can maximize productivity and promote continuous improvement at your plant.
The wireless Andon system
While traditional Andon systems tend to be expensive, time-consuming to install, and not very flexible, Wilson’s wireless invention is easy to deploy and add to over time. The web-based system gives you a visual representation of the status of your line that you can check anytime, anywhere, on any device.

 
Simple and customizable
The Andon system is user-friendly and easy to customize. You can set it up to suit your exact needs today—and tomorrow, as your plant evolves.

 
Multiple usage levels
You can use the wireless Andon system at different levels, from entry to advanced. At the entry level, the system lets you spot problems and shorten response times through an online display board and email/text notifications. As you become more familiar with the system, you can use it to analyze downtimes, create incident reports, monitor problem areas, prioritize key tasks, and schedule maintenance.

 
The escalation process
The wireless Andon system can be programmed to include different levels of escalation based on your priorities and urgency levels. For instance, if the line is down for 10 minutes, a notification is sent to the team leader. But if the issue isn’t addressed within, say, 30 minutes, the issue is escalated to the next level and a manager is notified.

Reporting events
Every time a notification is sent, the system records all the related data. You can also add more details to it. You can then go back, filter the information, and use it to monitor workstations, fix recurring issues, or make improvements.

Why not just jot everything down manually, like Toyota?
At Toyota, when an employee pulls the cord to alert a supervisor, they record the event manually, based on their interpretation. The reports are then placed in a stack that is eventually sorted by hand to see what needs attention. Not exactly streamlined!

What’s OEEE?
You’re likely familiar with OEE: overall equipment effectiveness. But you probably don’t have detailed data about your employees and workstations. With the wireless Andon system, however, you get OEEE data: overall equipment and employee effectiveness.

Want to make your manual operations more efficient? Contact Industrial Andons for more information.

 
About our guest speaker Bob Wilson

Bob Wilson is the owner of Industrial Andons and Jidoka Consulting. Bob invented, patented and developed a wireless Andon system used by companies across a broad range of industries to greatly improve their quality and productivity. He started his lean learning while working for Toyota and Ford, experiences that led him to become a Kaizen Circle Leader and to earn a Six Sigma Black Belt Certification.

Bob has worked on lean implementation projects ranging from the shop floor to engineering and business processes. At AMD, he led the Lean Engineering Team, launched and led the Lean Academy and the Lean Global Ops team, and currently works on Strategy and Innovation.

Bob co-authored the book First, Fire the Consultants! published in 2020.

Website: industrialandons.com
Contact: industrialandons.com/contact
Phone: 1-866-290-7551

Many engineers are making the mistake of using T-slot aluminum extrusions everywhere on their production line. Here's how to avoid creating overkill, overbuilt, and overpaid structures.

This guide will cover the following:

What Are the Advantages of Each System?
How to Choose a Modular Systems?
What Type of Structure do You Want to Build?
What Loading Capacity Do You Need?
Does Your Structure Will Evolve Over Time?
What's Your Budget?
Is the Aesthetics a Priority?
Takeaway

Determine the loading capacity of a structure using our CAPACITY CHARGE CALCULATOR.

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What Are the Advantages of Each System?
These modular systems should not be considered competitors because they have their unique advantages and should be used in deferent situations. Because T-slot aluminum constructions are sturdier and more precise, they are an obvious choice for production systems involving robotics and automation. On the other hand, the pipe and joints system, perfectly embody the Lean Manufacturing concept. It's simple to assemble and customize while also been more affordable.

Pipes and Joints

Much lower pricing
Structures can be assembled faster
Easy to design and assemble
Order online
Structures can be easily tested, improved and adapted for lean purposes

T-slot Aluminum Extrusions

Heavier load/charging capacity
Make sturdier structures that can take rapid and repetitive movements
Modern and sleek style 
More precision
Ideal for jigs and robotics
More components and parts to integrate robotics and automation systems

How to Choose a Modular Systems?
When analyzing different modular system options to implement or adapt a production line, a lot must be considered. Maximizing a production floor's efficiency, ensuring employees are working in a safe, ergonomic manner, and ensuring the production blueprint can be adapted over time are key points to keep in mind throughout the conceptualization process.

While both T-slot aluminum profiles such as 80/20's or Vention's and tubular systems like Flexpipe's offer great solutions to manufacturers and design engineers. The products have unique characteristics that will influence how they will be of better use in a production context.

What Type of Structure do You Want to Build?
Because T-slot aluminum constructions are sturdier, they are an obvious choice for production systems involving robotics and automation. 

They are made with refined equipment that can offer very tight tolerances. Their durable and resistant nature can also support a variety of robotic applications facing rapid and repetitive movement, such as:

Framing for robotic mounting structures
Jigs and fixtures
Automation systems
High precision conveyor systems or assembly station

It's A Matter of High Precision
There is an intubation space of 1 inch in the tubular system when you insert the pipes into the fittings -even if the tubes should be fully inserted. This remaining space makes the assembly process easier by giving a margin of error for small cutting or design mistakes. 

While this detail might come in handy in some contexts, the facts remain: tubular structures are not as precise as aluminum framing systems. 
The tubes and fittings structures are more adapted to other types of use. 
Here are a few examples of various material handling systems that would be more efficiently built with pipes and joints than aluminum extrusions.  

It would be considered "overkill, overbuilt and overpaid" if you consider building the following structure with aluminum extrusions:

Flow racks 

Return lines for empty containers to ensure continuous production. 
Supermarket racks to have stock nearby.
L-shaped flow racks for the proximity of parts.
One-piece flow conveyor stations for lean manufacturing.
Gravity-fed workstations to free up floor space.

For more information on flow racks, check out this article on the most common types of modular gravity flow racks and how they can increase production line efficiency.

Racks

Adaptable racks.
Shelving with added value. 
WIP racks to reduce defects.
Storage racks are intended as a poka-yoke.

For more information on racks, check out this guide on the most popular modular industrial racks and shelving systems.

Workstations and workbenches 

U-Cell stations will improve your lead time. 
Ergonomic stand-up stations and work centers are great to have task-relevant information nearby. 
Personalized adjustable working tables are perfect to meet your worker's needs. 
ESD workstations to reduce defects.

For more information on workstations and workbenches, check out this guide on the different types of custom-made industrial workstations & workbenches.

Modular boards

Point-of-use or shadow boards.
Rotating cube and 8-faced boards.
Meeting space.
1, 2, 3, or 4 sided boards.

For more information on boards, check out these types of modular boards.

Carts

Kitting carts.
Tuggable carts.
WIP carts
Warehouse picking carts.
Truck carts.

For more information on carts, check out this guide on the popular types of carts for industrial material handling.

What Loading Capacity Do You Need?
The most robust structures made with the pipe and joint systems can support a maximum charge of 2000 pounds!

Pipe and joint systems like Flexpipe mostly use 28 mm OD pipes, with or without plastic coatings. The thickness of the pipes generally varies between 1 and 2 mm, providing various solidity levels which can be adapted to the project's specifications. But since the tube's diameter stays the same, Flexpipe structures will never be as strong as aluminum extrusions structures. The metal joints and various fasteners also contribute to the strength of the frame.
For more information on loading capacities, check out this guide created to help you calculate the modular structures' loading capacity.

Determine the loading capacity of a structure using our CAPACITY CHARGE CALCULATOR.

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Being able to choose between different sizes of profiles ranging from 20 millimeters square to as large as 180 by 360 millimeters makes t-slot profiles a perfect option for projects involving very heavy loads.

T-slotted aluminum profiles are offered in different types and sizes, the most popular being the 6063-T5, often ranging from 1 X 1" to 1,5 X 1,5" inches. The choices in inch or millimeter square make it an excellent choice for light to heavy-duty framing projects.

According to this article on Formaspace, the biggest aluminum profiles used to make 80/20 extruded frames carry very heavy charges: 6105-T5 aluminum alloy has a tensile strength of 35,000 lbs. per square inch! 

Does Your Structure Will Evolve Over Time?
Because of the lower costs of pipes and fittings "modular systems" and the simplicity of the tubular approach, tests can be carried out more easily before implementing new structures. Manufacturers can, therefore, quickly reconfigure a wide range of assembly line components based on feedback, with minimal capital outlay. 

Engineers can spend more time brainstorming and continually optimizing assembly processes. Rather than designing each structure from scratch, resulting in higher employee satisfaction and optimization of the production process!

Because pipes and fittings systems are more straightforward and involve fewer components, it's easier for engineers to shop online, figure out how they can use the product for their specific needs, and become creative more quickly! 

It's also easier for employees working on the assembly lines to get involved in the optimization process, stay proactive, and improve their work tools. Which is excellent for professional satisfaction and motivation!

Since the cost is higher, the testing part becomes more expensive and financially risky with the aluminum extrusion profiles. Making the whole testing and trying process more complicated than it is with the tubular system. This constraint tends to result in a longer, more complex planning process when creating new modular structures. 
Adapting and Evolving: a Constant Concept
Perfectly embodying the Lean Manufacturing concept, the Flexpipe production systems can easily be adapted to follow the production's new needs and reality. The simplicity of the structures ensures that any changes can be applied quickly and tested right away, thus leaving room for errors and constant improvement along the way.

Modifying already existing T-slot frames is a little more complex since they're also more complicated to assemble in the first place. Because of the various components involved in the system, the modular aspect of the structures is not as easily adaptable to feedback and testing. On the other hand, the multiple parts open up more options and possibilities for robotic integration and automation of specialized types of systems.

What's Your Budget?
Although the products' cost varies depending on the specifications of the project, aluminum tends to be about 30% more expensive than Flexpipe. 

For some manufacturing companies designing and working with an important number of workstations and production systems, the choice of material becomes very important. General application has a significant importance when it comes to choosing the best option. 

However, when it comes to intra-logistic applications where push-carts and flow racks are required, the cost and flexibility of pipe and joints systems trump T-slot aluminum extrusion profiles.

Is the Aesthetics a Priority?
Some professionals like the sober, straight lines, and modern looks of the T-slot aluminum profiles. Therefore, it could be considered a better choice for the aesthetics of their framing system. 

While it is possible to buy colored aluminum extrusions, it is more common to see clear aluminum finish or the typical blueish color of anodized aluminum often seen on Vention's extrusions for example, because of the considerable costs involving the powder coating process for coloration. 

On top of the traditional black and stainless colors, tubular systems like Flexpipe offer blue, yellow, green, white, red, orange, gray, and ivory colored tubes. The choices in colors mostly aim to make it easier to use color-coding systems on a production floor. Still, they can also bring a lighter atmosphere to a work environment! 

If you're looking for a sleeker, sober look, Flexpipe's stainless tubes matched with chrome-plated joints could very well match your taste. 
To better visualize what a pipe and joint structure look like, check out our photo gallery featuring structures assembled internally by the Flexpipe team.

Takeaway
While both products offer customized, creative and efficient solutions in various production structures, their technical particularities make their use complementary. 

Each of them is more appropriate in different contexts of the production system. On your typical assembly line, any robotics or automation-related construction system will likely be more productive and precise if built with t-slotted aluminum profiles. On the other hand, pipes and fittings systems will be the obvious choice when building flow racks, workstations, modular boards, or carts!

Temie Fessa, a project manager for Flexpipe who has been working in the field for over ten years, says many of his clients will use both systems in different contexts. He points out that when engineers or consultants have been using aluminum extrusions on their production line for a long time, they'll tend to keep the same habits when designing new structures, as a professional legacy. Because they are so used to the t-slot aluminum framings, they won't question their choices or look for other options unless they are given a specific assignment related to budget cuts, for example.

And since the price of steel tubes and fittings is much lower than aluminum extrusions, once they've discovered the tubular systems and how easy it is to use, many companies will start integrating the tubular products as much as they can in the production environment. Especially when they don't need the heavy-duty aspect or the precision provided by the strut profiles. Using steel pipes tubular systems, therefore, allows them to cut the costs without any downside.

In the current crisis, companies must quickly adapt their production. Certain security measures will be necessary to ensure the protection of all employees. You will find in this page a panoply of protectives structures that want to be inspiring, simple to realize, and at a low price.

Why buying Flexpipe in the pandemic situation?
The needs linked to Covid-19 being temporary, when the pandemic is over, it is very easy to dismantle the tubes and joints in order to transform them into other workstation designs and find them a second life! You'll find two types of structures below: the ready to assemble kits and inspirations for customized protective structures.
5 READY TO ASSEMBLE KITS
Typically, contagions are passed when individuals are within 6 feet of each other. Coughing and sneezing, which can introduce potentially contaminated droplets into the air, is one of the main ways COVID-19 is being spread. Here are 5 sneeze guards kits to protect your clients and employees.

- 36x72 Sneeze guard assembly kit - 175$
- 48x71 Sneeze wall assembly kit - 205$
- 32x32 Sneeze Screen assembly kit - 99$
- 20x30 1/2 Sneeze side assembly kit - 99$

Take a look at all the kits

Watch the assembly video

How to recycle your Sneeze guard pipes and joints after the crisis (an example)

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CUSTOMIZED PROTECTION STRUCTURES
Protectives separators between production employees
Here are some customized inspirations. All of these ideas are adaptable. Our strength is tailor-made! Send us the required dimensions and we will assist you in the preparation of your project.

We can design plans quickly.
We can pre-cut and send you kits.
We can pre-assembled structures and deliver turn-key projects.
Mass production can be put into rapid action.

DOWNLOAD ALL COVID-19 PROTECTION STRUCTURE HERE
Line guard: download this plan

Assembly line dividers and protectors
Sneeze guard: download this plan

Sneeze guard: download this plan

Portable sneezeguards on casters with brakes.
Sneeze guard: download this plan

The next picture was sent by one of our favorite people in the Flexpipe Community! Jason Blain from Winpak who shared with us his brand new installation: sneeze guards that allow the workers to keep going in security.

And as he said, it was ''built while they were working and installed while they were on lunch. A fast but an effective build.'' Quick and simple!

Sneeze screen 32x32: download this plan

Sneeze wall: download this plan

Sneeze wall: download this plan

Employee / customer protection or for office workers
Sneeze screen 32x32: download this plan

Sneeze screen 32x32: download this plan

 
Cleaning and disinfection station

Handwashing station: download this plan

Hand sanitizer rack: download this plan

LET US KNOW IF YOU IF YOU HAVE A SPECIFIC REQUIREMENT - WE WILL GET BACK TO YOU IN 24 HOURS.

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WHAT CAN FLEXPIPE DO TO OPTIMIZE YOUR PLANT EFFICIENCY?

Flexpipe Modular materials handling systems can help you with implementing continuous improvement principles. Your team’s creativity can result in a 10% increase in productivity per year. It has been a proven system for more than 50 years now.

Here are examples of how medical manufacturers use the pipe and joint system for lean manufacturing. Below are several photos of various workstations: U and L-shaped work cells and one-piece flow assembly line, among others.

Manufacturers also use pipe and joint systems to build carts for different purposes: WIP, kitting cart, sub-assembly, etc. The structural system can also be used to build custom flow racks and 2-bin systems than can be integrated into the workstations.

Contrary to popular belief, innovation isn’t always the result of a costly and challenging process. Sometimes, a little imagination and resourcefulness are all it takes to solve recurring problems. The moonshine shop, a corporate continuous improvement concept, is part of a new trend built around that notion. Here are ten things you may not know about this increasingly popular practice.

Listen to Cesar Flores owner of consulting firm Lean Moonshine shop going deeper in every aspects of a moonshine shop, from getting started to budget aspects.

Issue and ideas submitting process
Approval process
Space needed
Budget
How to calculate ROI

Download your printable PDF Moonshine shop checklist

1 - Moonshine shops were inspired by Prohibition
During the Prohibition era, from 1919 to 1933, Americans got creative and started making their alcohol, often at night by the light of the moon, from whatever materials and food (fruit, vegetables, etc.) they had on hand. This illegal liquor was dubbed “moonshine.”
2 - Toyota, a continuous improvement pioneer
[caption id="attachment_26468" align="alignnone" width="814"] Photo: The moonshine is directly connected with the human factor of the lean concept since the operators and assemblers who take part in the production chain are always invited to suggest improvements. They are the main players in a moonshine. Source: thedrive.com[/caption]

Without Toyota, the moonshine shop would probably have never come about. From 1948 to 1975, the automotive giant developed the famous Toyota Production System (TPS), a corporate philosophy that sought to find the most efficient production methods while eliminating waste.

Associated with what’s known in North America as “lean manufacturing,” TPS has inspired a variety of related concepts. Chihiro Nakao, founder of the Shingijutsu Company and a former Toyota employee, used TPS as a springboard to develop the moonshine shop.

 
3 - Failure is part of the process
In a moonshine shop, employees use simple and inexpensive materials to find solutions to problems they encounter in their day-to-day work. Using affordable materials means fewer budget constraints and lets employees give free rein to their creativity.

What’s more, that a fear of failure doesn’t hinder creativity. Quite the opposite—failure is a normal part of the creative process. For instance, if employees in a moonshine shop design an inefficient forklift, they don’t need to be afraid of being reprimanded by their superiors for wasting valuable company resources. They just roll up their sleeves and find a way to make it better. They might use protostorming and trystorming, which make it easy to create simple physical prototypes quickly.

Here's a good example of how to sketch processes and ideas while doing a brainstorm with the team.



At GE the mocking-up process is very important. And here again, the emphasis is put on the energy deployed around an improvement. It does not need to be big and beyond expectations to be put in place. After having evaluated all aspects, the actions taken have to be accordingly to the real needs and not bigger.


4 - Working together to find solutions is the most significant advantage

One of the main advantages of the moonshine shop is how fast you can implement improvements. For example, if an employee regularly performs a non-ergonomic movement, they can report the problem to the moonshine shop manager.

Instead of calling a subcontractor and waiting months for them to come and adjust the employee’s workstation, the manager (often called the “lean sensei”) can quickly come up with and implement a solution. The employee will be happy and feel like the company cares about them. This will encourage them to contribute other ideas, helping foster a culture of innovation within the company.

[caption id="attachment_26473" align="alignnone" width="814"] At Avio Aero plant in Bielsko-Biała the notion of working together is key to success. Source: magazineabout.com[/caption]

At Avio Aero plan in Bielsko-Biala Employees on the production line are here again submitting their ideas to the Moonshine shop manager via email or submission forms that are available everywhere on the plant. The moonshine shop manager will prioritize requests and organize a shop where different types of employees will be invited. It is good to also include workers outside the process to get some fresh ideas and perspectives.
5 - Moonshine shops foster innovation

If you’re already using other concepts to improve and optimize corporate processes and productivity, such as protostorming, trystorming, kaizen, Karakuri, or the 5S method, you’ll be happy to know that a moonshine shop is fully compatible with and complementary to these concepts.
6 - Suitable for any company

Simple to set up, moonshine shops aren’t just for multinationals like Toyota. Small- and medium-sized companies can also reap the benefits.

At Flexpipe, for instance, employees who want to cut down on physical waste can use a board. Using sketches, they first describe the current situation and then propose a solution. Once they are finished, the Continuous Improvement Committee, composed of four or five people, evaluates their proposal.

If the solution is approved, several employees are released from their regular duties to work in the moonshine shop. Using basic tools (saw, measuring tape, Allen wrenches, worktable, storage unit, etc.) and other materials, such as Flexpipe pipes and joints, wheels, and magnets, they make the solution proposed by their coworkers.

 
7 – Maintenance is not moonshine
Your company probably has a department that deals with everyday issues at the plant. These experts monitor, control, and maintain the equipment regularly to avoid breakdowns that could affect productivity. Although the moonshine shop shares this same principle, it has a different goal.

Instead of performing corrective and preventive maintenance, moonshine shop employees focus on continuously improving corporate processes. Rather than simply repairing a damaged workstation, they find ways to improve it so that it is out of service less often.

At Boeing, moonshining is everyone's business, but there are also people dedicated to it full-time. Efforts have been made to ensure that lean and continuous improvement workshops are applied outside of the production environment. Boeing in Seattle has therefore created a model of continuous improvement modeled on the philosophy of the moonshine with employees who, naturally, have a maintenance profile. The maintenance people are very creative and resourceful. It is also characteristic of the moonshine shop. This combination is undoubtedly a winner! But even though, don't forget that maintenance and Moonshine shops are two separate and totally different activities.

[caption id="attachment_26446" align="alignnone" width="429"] Moonshine shop at Boeing. Source: reliableplant.com[/caption]

Even though production at Boeing is on a large scale, the goal of the moonshine shop is on a small scale. We must ask ourselves the following question: should we deploy costly, extravagant, and time-consuming solutions to solve problems that require targeted and rapid actions at workstations that have a more or less limited lifespan.

Consult this entire slide presentation to know more about Moonshine process at Boeing

And, just because we like to see this video again and again, here's the famous time-lapse video of a Boeing 737 construction!



 
8 – Support from management is essential
[caption id="attachment_42420" align="alignnone" width="714"] Overview of a training space and continuous improvement workshop of a company in the packaging industry.[/caption]

Even with the best intentions in the world, a moonshine shop cannot be useful without constant and unwavering support from management. Senior management should keep in mind that employees assigned to this department will inevitably make mistakes and possibly “waste” company time and resources.

What’s more, although a moonshine shop is inexpensive to set up, it needs an operating budget and a certain degree of structure. It also requires a manager to serve as the go-between for employees and management, to ensure, among other things, that projects are running smoothly.

 
9 – Ideally, employees should receive value-added management training

Since the moonshine shop is a tool for implementing value-added production initiatives, there must already be a value-added management culture within the company. It’s better if your employees, especially the moonshine shop manager, have received prior training in value-added management and its related concepts, such as protostorming and trystorming. They should also be familiar with the eight wastes and the 5S method. Once trained, employees can take full advantage of a moonshine shop.

 
10 – A moonshine shop doesn’t have to take up a lot of space

To set up an efficient and productive moonshine shop, you need a dedicated space at the plant, equipped with basic tools and materials. For example, some companies have a moonshine shop right in the middle of their facility so that employees can see innovative work taking place in real-time.

But some small businesses feel they don’t have the space to set up this kind of initiative. If this is the case for you, you should know that there are lots of different solutions, such as folding units, that let you set up a moonshine shop in a relatively small space.

In short, there’s no excuse for not setting up a moonshine shop at your company. After all, continuous improvement is a collective responsibility!
WEBINAR about Moonshine shops  - extra tips


 
What do you need to build your own Crib or Moonshine shop?


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Visit Lean Moonshine shop 

Lean Moonshine Shop Specializes in real Kaizen/ Kaikaku implementation, Lean Manufacturing, Lean Process Improvement and problem-solving.