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Lean suggests the elimination of large packaging. The use of small lots often requires constant supply. Gravity flowracks help realize this approach with a continuous flow in the factory. Flowracks are usually supplied from behind and parts are consumed on the other side. Gravity racks can be used on the assembly lines or in the storage areas. The pipe and joint system facilitates the building of these custom roller racks.
The idea is simple: swap the palette of large material containers next to the employee (often representing one or two days of production) for a flowrack, with small containers representing several hours of production and keeping the presentation neat.
This idea can easily be included in your organization during the design of a lean manufacturing workstation. The flow racks are not new, they were first known for their use in supermarkets for perishable items such as milk. Then in distribution centers with first-in-first-out racking systems (FIFO), but they are now present on assembly lines, services and even in the health system.
Using small lots and small containers, gives you the possibility to use parts in a flow mode to transport parts at low cost, to easily follow operation schedules and adjust to possible changes. This will also allow you to save space on the production line, improve the part presentation and organize better workstations. An increase in productivity and an increase in production line density (the production volume per unit area) will be quickly achieved.
For several years, organizations using fifo racks have seen the following benefits:
Supplies are more organized
Unlike a standard shelf, a flowrack requires a way to operate: Supplying from behind and consumption in front. This allows two people to accomplish their tasks without interference. Travel is also minimized, because all products are found together in one place.
Merchandise is more organized
Some items may be more difficult to store because of their shape. The organization and preparation of components in a flowrack also eliminates wasted time searching for and unpacking parts.
To facilitate the work of the operator, the flowrack can be integrated into a workstation. Some travel and unnecessary manoeuvres could be eliminated. The ergonomics of the workstation must also be considered in the design of a position.
Using our pipe material handling system made of pipes and joints, you can easily build or order your custom flowracks with Flexpipe.