{"id":70099,"date":"2026-04-10T16:21:56","date_gmt":"2026-04-10T20:21:56","guid":{"rendered":"https:\/\/www.flexpipeinc.com\/?post_type=structure&#038;p=70099"},"modified":"2026-04-10T16:22:01","modified_gmt":"2026-04-10T20:22:01","slug":"wip-carts-lean-manufacturing","status":"publish","type":"structure","link":"https:\/\/www.flexpipeinc.com\/us_en\/structure\/cart\/wip-carts-lean-manufacturing\/","title":{"rendered":"WIP Carts"},"content":{"rendered":"\n<div class=\"wp-block-group typography\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"610\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart.jpg\" alt=\"hybrid material handling setup composed of two carts linked in a mother-daughter configuration. The base structures use 80\/20 aluminum extrusion, while the vertical and flow rack components are built from Flexpipe's black-coated steel tubes. One cart includes a flat working surface, and the other features three roller track flow levels for efficient kitting or parts presentation. Blue polyurethane casters and tow bar integration support tugger train logistics.\" class=\"wp-image-66800\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart.jpg 1200w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-768x390.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-375x191.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-1024x521.jpg 1024w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-24x12.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-36x18.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-48x24.jpg 48w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-500x254.jpg 500w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2025\/06\/Hybrid-Kitting-Cart-Pushing-Cart-800x407.jpg 800w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/><\/figure>\n\n\n\n<p>How a Modular and Scalable&nbsp;Lean&nbsp;Flexpipe&nbsp;WIP Cart Dramatically Reduces Bottlenecks, Improves Workflow, and Increases Efficiency and Production Throughput.<\/p>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group padding-global-30 is-style-default has-background\" style=\"background-color:#e2e2e2\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<h3 class=\"wp-block-heading\">Key Takeaways<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A&nbsp;WIP Cart&nbsp;Improves&nbsp;Workflow.<\/li>\n\n\n\n<li>A&nbsp;WIP Cart Reduces&nbsp;Bottlenecks.<\/li>\n\n\n\n<li>WIP Carts&nbsp;Improve Productivity and Efficiency.<\/li>\n\n\n\n<li>WIP Carts Protect Parts.<\/li>\n\n\n\n<li>Flexpipe&nbsp;Allows for Modular Designs for Rapid Configuration.<\/li>\n\n\n\n<li>Flexpipe&nbsp;Empowers Full Customization of Mobile WIP Carts.<\/li>\n\n\n\n<li>Flexpipe&nbsp;Modular&nbsp;Material Handling&nbsp;Reduces Material Handling Costs.<\/li>\n<\/ul>\n<\/div><\/div>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">1. WIP Carts: Modular Lean Work-In-Progress Handling Solutions for Canadian Manufacturing<\/h2>\n\n\n\n<p>In lean manufacturing, a work-in-process (WIP) cart is critical to&nbsp;eliminating&nbsp;waste and ensuring high efficiency and improved productivity. However, a steel-welded WIP cart is not lean. A steel-welded&nbsp;WIP handling cart&nbsp;can\u2019t&nbsp;be&nbsp;modified&nbsp;without substantial costs and&nbsp;extended downtime.<\/p>\n\n\n\n<p>What is needed is a&nbsp;<a href=\"https:\/\/www.flexpipeinc.com\/us_en\/structure\/cart\/\">WIP storage cart<\/a>&nbsp;made from&nbsp;Flexpipe&nbsp;steel tubes, joints,&nbsp;and accessories that can be&nbsp;modified&nbsp;as lean manufacturing needs evolve. A&nbsp;Flexpipe&nbsp;mobile WIP cart&nbsp;eliminates&nbsp;bottlenecks, reduces damage to semi-finished parts, increases visibility, and ensures a customized location for all work-in-process and semi-finished parts.<\/p>\n\n\n\n<p>The result is&nbsp;a modular and scalable WIP&nbsp;storage&nbsp;cart whose layout, dimensions, levels, and bin storage can all be customized and&nbsp;modified&nbsp;to keep up with changing production requirements.<\/p>\n\n\n\n<p>From improving workflow, mitigating damage, freeing up excess WIP inventory, to reducing the costs of material handling structures, the&nbsp;Flexpipe&nbsp;solution is the ultimate lean manufacturing accessory.<\/p>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">2. What Is a WIP Cart?<\/h2>\n\n\n\n<p>A work-in-process cart is a temporary storage cart that holds&nbsp;and&nbsp;moves semi-finished parts&nbsp;between lean manufacturing workstations.<\/p>\n\n\n\n<p>In lean manufacturing environments, continuous improvement is an absolute must. As such, a&nbsp;modular&nbsp;WIP cart must accommodate changing production requirements,&nbsp;meaning production teams must be able to&nbsp;modify&nbsp;the cart\u2019s size and layout as needed.<\/p>\n\n\n\n<p>Steel-welded carts and fixed carts do not allow for that change. However,&nbsp;Flexpipe&nbsp;does.<\/p>\n\n\n\n<p>There are several variations of WIP Carts. These include kitting and picking carts&nbsp;and&nbsp;tugger carts.<\/p>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Kitting Carts<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>A manufacturing kitting cart is used to gather all the materials and subcomponent parts needed to make and assemble a specific volume of finished goods. Kitting carts have locations for customized trays and bins as well as a leveled surface.<\/p>\n\n\n\n<p>The materials and subcomponent parts in kitting carts are linked to manufacturing work orders, which define the type of product being manufactured and assembled, as well as the volume needed.<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1000\" height=\"1000\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/za-jn1611-kitting-cart-for-airplane-furniture-400x400-c.jpg\" alt=\"Kitting Carts\" class=\"wp-image-7579\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/za-jn1611-kitting-cart-for-airplane-furniture-400x400-c.jpg 1000w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/za-jn1611-kitting-cart-for-airplane-furniture-400x400-c-150x150.jpg 150w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/za-jn1611-kitting-cart-for-airplane-furniture-400x400-c-375x375.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/za-jn1611-kitting-cart-for-airplane-furniture-400x400-c-768x768.jpg 768w\" sizes=\"auto, (max-width: 1000px) 100vw, 1000px\" \/><\/figure>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Picking Carts<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1000\" height=\"1000\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/fca-sv1601-picking-cart-for-automobile-component-boxes-3-400x400-c.jpg\" alt=\"Warehouse picking carts\" class=\"wp-image-7588\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/fca-sv1601-picking-cart-for-automobile-component-boxes-3-400x400-c.jpg 1000w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/fca-sv1601-picking-cart-for-automobile-component-boxes-3-400x400-c-150x150.jpg 150w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/fca-sv1601-picking-cart-for-automobile-component-boxes-3-400x400-c-375x375.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2017\/01\/fca-sv1601-picking-cart-for-automobile-component-boxes-3-400x400-c-768x768.jpg 768w\" sizes=\"auto, (max-width: 1000px) 100vw, 1000px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>Picking carts are&nbsp;essentially order&nbsp;fulfillment carts. They are used with warehouses to allow inventory personnel to pick parts to complete a given customer order. In this case, the picking carts allow the warehouse employee to pick finished parts stored on inventory shelves.&nbsp;These picking carts typically have a leveled surface for easy counting and for storing an RFID scanner.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Tugger Carts<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p><a href=\"https:\/\/www.flexpipeinc.com\/us_en\/structure\/cart\/tugger-carts\/\">Tugger&nbsp;carts<\/a>&nbsp;are connected carts that are either manually pulled by a production or warehouse employee or pulled by a battery-operated tugger.<\/p>\n\n\n\n<p>While small&nbsp;tugger&nbsp;carts&nbsp;can sometimes be pulled by a production employee, the most ergonomic and safety-first solution includes carts being pulled by a battery-operated tugger. This allows the employee to maneuver the tugger carts without any strain.<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1000\" height=\"562\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view.jpg\" alt=\"\" class=\"wp-image-70052\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view.jpg 1000w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-768x432.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-375x211.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-710x400.jpg 710w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-24x13.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-36x20.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-48x27.jpg 48w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-500x281.jpg 500w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/hybrid_cart_side_view-800x450.jpg 800w\" sizes=\"auto, (max-width: 1000px) 100vw, 1000px\" \/><\/figure>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">3. Why WIP Control Is Critical in Lean Manufacturing<\/h2>\n\n\n\n<p>Within lean manufacturing environments, controlling the volume of work-in-process (WIP) parts is critical to&nbsp;maintaining&nbsp;a manageable and uninterrupted workflow without delays, waste, extra costs,&nbsp;or&nbsp;bottlenecks.&nbsp;It\u2019s&nbsp;a balancing act: Too high a volume of WIP leads to overproduction and waste,&nbsp;while&nbsp;too low a volume of WIP leads to&nbsp;production inefficiency and lost time.<\/p>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Multiple Workstations to Complete a Product<\/h3>\n\n\n\n<p>Within any&nbsp;lean manufacturing production process, a part has a beginning and an end. Materials are kitted and transported to the first workstation within a kitting cart. That workstation performs its work task, and the semi-finished part moves to the next workstation or chain in the production process. The kitting cart moves the semi-finished goods&nbsp;to each adjacent workstation&nbsp;until the part is finished and ready to ship.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1000\" height=\"1000\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN.png\" alt=\"\" class=\"wp-image-70056\" style=\"aspect-ratio:4\/3;object-fit:contain\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN.png 1000w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-150x150.png 150w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-768x768.png 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-375x375.png 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-24x24.png 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-36x36.png 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-48x48.png 48w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-500x500.png 500w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Adopt_Kaizen_EN-800x800.png 800w\" sizes=\"auto, (max-width: 1000px) 100vw, 1000px\" \/><\/figure>\n<\/div>\n\n\n<p>If there is too much WIP, then bottlenecks occur, and the entire chain can suffer lost time where employees are paid without&nbsp;enough&nbsp;work. Conversely, if there&nbsp;isn\u2019t&nbsp;enough WIP, then the same result occurs as some workstations will have production employees sitting idle, waiting for work.<\/p>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Processes to Help Control WIP<\/h3>\n\n\n\n<p>The following approaches are commonly used in lean manufacturing environments to better manage WIP levels. In practice, achieving&nbsp;optimal&nbsp;WIP control often requires a combination of these methods rather than relying on a single approach.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h4 class=\"wp-block-heading\">&#8211; One-Piece Flow<\/h4>\n\n\n\n<p>In a one-piece flow system, products move through the production process one unit at a time instead of in batches. This reduces the amount of WIP in circulation and helps create a more balanced and continuous flow.<\/p>\n\n\n\n<p><strong>Reality :<\/strong> In practice, very few manufacturing environments can fully implement one-piece flow. Producing one unit at a time often limits the ability to achieve economies of scale and may not be&nbsp;viable&nbsp;for all operations.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h4 class=\"wp-block-heading\">&#8211; Pull Systems<\/h4>\n\n\n\n<p>Pull systems are demand-driven, meaning production is triggered by actual customer orders rather than forecasts. To&nbsp;maintain&nbsp;efficiency and avoid the limitations of one-piece flow, manufacturers typically define a minimum order quantity (MOQ).&nbsp;<\/p>\n\n\n\n<p><strong>Reality :<\/strong>&nbsp;While pull systems improve WIP control, they also introduce complexity. Manufacturers must account for product variability, as different configurations often require unique setups and have varying cycle times.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h4 class=\"wp-block-heading\">&#8211; Cycle Time Management<\/h4>\n\n\n\n<p>Every operation has a defined cycle time. Continuously improving cycle times enables each workstation to increase its output and overall productivity.&nbsp;Continuous improvement initiatives that reduce assembly time directly contribute to higher throughput.<\/p>\n\n\n\n<p><strong>Reality :<\/strong>&nbsp;While cycle time management is fundamental in lean manufacturing, the real&nbsp;objective&nbsp;is to balance production across all workstations. Increasing throughput at one station can create downstream bottlenecks if the next process cannot keep pace.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h4 class=\"wp-block-heading\">&#8211; Buffer Management<\/h4>\n\n\n\n<p>Buffer management involves&nbsp;maintaining&nbsp;a controlled level of inventory between workstations. This ensures that each station has enough work to&nbsp;operate&nbsp;efficiently without interruptions or idle time.&nbsp;<\/p>\n\n\n\n<p><strong>Reality :<\/strong>&nbsp;Although buffers help stabilize production flow, they must be carefully managed. Excess buffer inventory can interfere with responsiveness to actual customer demand and lead to inefficiencies.<\/p>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Outcome of WIP Control and Optimized WIP Volume<\/strong>s<\/h3>\n\n\n\n<p>The ultimate benefit of WIP&nbsp;control is waste reduction. The ideal WIP volume means your manufacturing&nbsp;doesn\u2019t&nbsp;encounter&nbsp;the&nbsp;high costs&nbsp;associated with excess inventory, lost, idle or downtime in&nbsp;workstations,&nbsp;and excess semi-finished part handling.<\/p>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">4. Benefits of Modular WIP Carts vs Welded Structures<\/h2>\n\n\n\n<p>In&nbsp;lean manufacturing&nbsp;environments, change is a constant.&nbsp;Production requirements, part sizes, materials, consumables, and production layouts all change.<\/p>\n\n\n\n<p>Continuous improvement is about always striving to be better. Whether&nbsp;it\u2019s&nbsp;modifying&nbsp;a production line, workstation, lean work cell, or trying to find the perfect WIP volume, none of these pursuits work with steel-welded carts or steel-welded workstations and material handling structures.<\/p>\n\n\n\n<p>Steel-welded and fixed-in-place material handling solutions&nbsp;can\u2019t&nbsp;be changed without incurring weeks of downtime and significant rework costs.<\/p>\n\n\n\n<p>In every measurable way, a modular&nbsp;Flexpipe&nbsp;material handling structure is vastly superior.<\/p>\n\n\n\n<div class=\"wp-block-essential-blocks-pro-data-table  root-eb-data-table-ebuh6\"><div class=\"eb-parent-wrapper eb-parent-eb-data-table-ebuh6 \"><div class=\"eb-data-table-ebuh6 eb-data-table-wrapper\"><div class=\"eb-data-table-wrapper-inner\" data-post-id=\"70099\" data-block-id=\"eb-data-table-ebuh6\" data-source=\"static\" data-google-sync=\"true\" data-hide-header=\"false\" data-fixed-header=\"false\" data-show-pagination=\"false\" data-show-search=\"false\" data-fixed-header-scroll-height=\"300\"><\/div><\/div><\/div><\/div>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">5. Where to Use WIP Carts on the Production Floor<\/h2>\n\n\n\n<p>The primary purpose of WIP carts is to move semi-finished parts from one&nbsp;production stage (workstation)&nbsp;to the next.&nbsp;You\u2019ll&nbsp;find WIP carts moving parts from machining and drilling to polishing and assembly. They are also found near testing stations and in-process quality control stops. From moving semi-finished parts through each workstation to moving finished parts to packaging and labeling, WIP carts are everywhere.<\/p>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">6. WIP Carts vs Flow Racks \u2013&nbsp;What\u2019s&nbsp;the Difference?<\/h2>\n\n\n\n<p>WIP carts are designed to transport semi-finished parts between workstations. They support controlled workflow and are essential for managing WIP levels and buffer zones within production environments.&nbsp;<\/p>\n\n\n\n<p>Flow racks, on the other hand, are static storage systems used to organize materials and consumables. They hold bins on inclined levels, allowing items to flow forward for easy access and efficient replenishment.<\/p>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column padding-global-30 has-background is-layout-flow wp-block-column-is-layout-flow\" style=\"background-color:#e8e8df\">\n<p><strong>WIP Carts :<\/strong><\/p>\n\n\n\n<p>Move semi-finished parts between production stages.<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column padding-global-30 has-background is-layout-flow wp-block-column-is-layout-flow\" style=\"background-color:#e8e8df\">\n<p><strong><strong>Flow Racks :<\/strong><\/strong><\/p>\n\n\n\n<p>Inventory presentation where material bins sit on angled shelves.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\">Mobile Flow Racks<\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"1167\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail.jpg\" alt=\"\" class=\"wp-image-70064\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail.jpg 800w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail-768x1120.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail-375x547.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail-16x24.jpg 16w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail-25x36.jpg 25w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail-33x48.jpg 33w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2026\/03\/Flowrack_Roller_Tracks_Hybrid_Cart_Detail-500x729.jpg 500w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-center is-layout-flow wp-block-column-is-layout-flow\">\n<p>A mobile flow rack is less of a&nbsp;WIP&nbsp;cart and more of a bin-retrieving solution that is&nbsp;immediately&nbsp;positioned beside a given lean workstation or work cell.&nbsp;A mobile flow rack is a&nbsp;<a href=\"https:\/\/8020.net\/material-handling\" target=\"_blank\" rel=\"noreferrer noopener\">material handling solution<\/a>&nbsp;that&nbsp;provides the&nbsp;consumables the assembly technician needs to complete a given work task.<\/p>\n\n\n\n<p>Mobile flow racks are often considered line-side racks because they are positioned alongside a given production line. Each level of the flow rack is angled at 15 degrees, and there is a stopper on each level to hold the bins in place.<\/p>\n\n\n\n<p>Technicians take bins from the front, and support personnel replace bins from the back. This simple solution keeps assembly employees within their workstations and working, instead of having to leave to retrieve material bins.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">7. Common Mistakes in WIP Management<\/h2>\n\n\n\n<p>There are several common mistakes that&nbsp;<a href=\"https:\/\/8020.net\/blog\/unleashing-efficiency-exploring-the-benefits-of-lean-methodology.html\" target=\"_blank\" rel=\"noreferrer noopener\">lean manufacturing<\/a>&nbsp;environments make with WIP management. First, they&nbsp;don\u2019t&nbsp;have sufficient WIP control. Second, they tend to use too large a buffer inventory, and too much inventory is costly.<\/p>\n\n\n\n<p>Third, overloading&nbsp;a mobile WIP cart&nbsp;is another all-too-common mistake that leads to damaged WIP or semi-finished parts. This is common with steel-welded carts, but less of a concern with&nbsp;Flexpipe&nbsp;WIP carts, as a&nbsp;Flexpipe&nbsp;WIP cart can be customized to hold a specific&nbsp;amount&nbsp;of parts.<\/p>\n\n\n\n<p>Not&nbsp;maintaining&nbsp;proper visibility on WIP volumes and not properly adjusting for changing product dimensions and requirements are other problems. Both are more common with steel-welded carts and less common with a&nbsp;Flexpipe&nbsp;WIP cart.<\/p>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group padding-global-30 is-style-default has-background\" style=\"background-color:#e2e2e2\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<h3 class=\"wp-block-heading\">Key WIP Management Mistakes<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Insufficient WIP control&nbsp;<\/li>\n\n\n\n<li>Excessive buffer inventory&nbsp;<\/li>\n\n\n\n<li>Overloading WIP carts&nbsp;<\/li>\n\n\n\n<li>Limited visibility of WIP levels&nbsp;<\/li>\n\n\n\n<li>Failure to adapt to changing product dimensions<\/li>\n<\/ul>\n<\/div><\/div>\n\n\n\n<div style=\"height:85px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Frequently Asked Questions About WIP Carts<\/h2>\n\n\n<div id=\"rank-math-faq\" class=\"rank-math-block\">\n<div class=\"rank-math-list \">\n<div id=\"faq-question-1774641334139\" class=\"rank-math-list-item\">\n<h3 class=\"rank-math-question \">What is a WIP cart used for?<\/h3>\n<div class=\"rank-math-answer \">\n\n<p>A work-in-process (WIP) cart is used in manufacturing to move semi-finished parts from one workstation to the next. It improves workflow while allowing workers to transport semi-finished parts through each production stage. A modular WIP cart made from\u00a0Flexpipe\u00a0steel tubes and joints\u00a0can be customized to the specific size of the semi-finished parts to reduce the likelihood of part and material damage.<\/p>\n\n<\/div>\n<\/div>\n<div id=\"faq-question-1774641389983\" class=\"rank-math-list-item\">\n<h3 class=\"rank-math-question \">How much weight can a WIP cart hold?<\/h3>\n<div class=\"rank-math-answer \">\n\n<p>The weight a WIP cart can support\u00a0depends on\u00a0the cart\u2019s design, materials, and the type of casters. Most industrial WIP carts can hold anywhere from 200 to 1,100 pounds. However,\u00a0the weight\u00a0a custom-designed and assembled\u00a0Flexpipe\u00a0mobile WIP cart can\u00a0support is\u00a0determined\u00a0using the\u00a0<a href=\"https:\/\/www.flexpipeinc.com\/us_en\/technical_data\/loading-capacity\/\">deflection calculator<\/a>.<\/p>\n\n<\/div>\n<\/div>\n<div id=\"faq-question-1774641405260\" class=\"rank-math-list-item\">\n<h3 class=\"rank-math-question \">Are WIP carts better than pallets?<\/h3>\n<div class=\"rank-math-answer \">\n\n<p>A\u00a0mobile\u00a0WIP cart is often preferred over pallets within manufacturing because a WIP cart is specifically designed to improve workflow between adjacent workstations. While a WIP cart is moved by production employees, a pallet often must be moved by forklift, given that pallets\u00a0are more often used to transport heavy raw materials.<\/p>\n\n<\/div>\n<\/div>\n<div id=\"faq-question-1774641419376\" class=\"rank-math-list-item\">\n<h3 class=\"rank-math-question \">Can modular WIP carts be\u00a0modified?<\/h3>\n<div class=\"rank-math-answer \">\n\n<p>A steel-welded WIP cart cannot be\u00a0modified\u00a0without incurring\u00a0high costs\u00a0and a long lead time, but a modular, scalable\u00a0Flexpipe\u00a0WIP cart can easily be\u00a0modified\u00a0by manufacturing employees.\u00a0A\u00a0Flexpipe\u00a0WIP cart can be changed as needed and\u00a0modified\u00a0on-site by production employees within a half hour to an afternoon, depending on the change\u00a0required.<\/p>\n\n<\/div>\n<\/div>\n<div id=\"faq-question-1774641432888\" class=\"rank-math-list-item\">\n<h3 class=\"rank-math-question \">Do WIP carts support lean manufacturing?<\/h3>\n<div class=\"rank-math-answer \">\n\n<p>Yes. A\u00a0mobile\u00a0WIP cart is ideal for moving semi-finished parts between workstations within lean manufacturing environments.\u00a0A modular WIP cart can\u00a0minimize transit times, reduce unnecessary movements, improve production processes, increase organization, and improve efficiencies while ensuring a more streamlined workflow with fewer roadblocks or idle time.<\/p>\n\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Design and Assemble Your Own Low-Cost, Durable WIP Cart Using the&nbsp;Flexpipe&nbsp;Material Handling System<\/strong><\/h2>\n\n\n\n<p>Lean manufacturing environments thrive on lean workflow control. That requires a willingness to constantly tweak and adjust your WIP to the ideal volume. However,&nbsp;it\u2019s&nbsp;never a one-time effort. Lean manufacturing means constant change and continuous improvement never ends.&nbsp;&nbsp;<\/p>\n\n\n\n<p>A lean manufacturing facility requires a cost-effective material handling system that allows for quick and immediate changes that are affordable, easy to&nbsp;initiate, and do not lead to substantial downtime.&nbsp;&nbsp;<\/p>\n\n\n\n<p>The&nbsp;Flexpipe&nbsp;material handling system is the ultimate lean manufacturing and continuous improvement solution.<\/p>\n<\/div><\/div>\n","protected":false},"author":7,"featured_media":7586,"parent":441,"menu_order":0,"template":"","meta":{"_acf_changed":false,"_eb_attr":"","content-type":"","inline_featured_image":false,"sfsi_plus_gutenberg_text_before_share":"","sfsi_plus_gutenberg_show_text_before_share":"","sfsi_plus_gutenberg_icon_type":"","sfsi_plus_gutenberg_icon_alignemt":"","sfsi_plus_gutenburg_max_per_row":"","_eb_data_table":"{\"eb-data-table-t0z5m\":{\"columns\":{\"col\":[\"Column 1\",\"Column 2\"],\"width\":[\"\",\"\"]},\"rows\":[[\"\",\"\"],[\"\",\"\"],[\"\",\"\"],[\"\",\"\"],[\"\",\"\"]]},\"eb-data-table-ebuh6\":{\"columns\":{\"col\":[\"COMPARISON TABLE\",\"\",\"\",\"\"],\"width\":[225,null,55,null]},\"rows\":[[\"Criteria\",\"Flexpipe Modular Carts\",\"VS\",\"Steel-Welded Carts\"],[\"Reconfiguration Speed\",\"Can be\u202fmodified\u202fin minutes or hours directly on the shop floor\",null,\"Requires cutting, welding, and downtime (days or weeks)\"],[\"Scalability\",\"Easily expandable or adjustable as production needs evolve\",null,\"Fixed size and structure, not scalable\"],[\"Layout Flexibility\",\"Fully customizable layout, dimensions, and levels\",null,\"Limited flexibility once built\"],[\"Modification Costs\",\"Low cost \u2013 simple adjustments using existing components\",null,\"High cost\u202f\u2013 requires labor, rework, and new materials\"]]}}","cybocfi_hide_featured_image":"yes","yasr_overall_rating":0,"yasr_post_is_review":"","yasr_auto_insert_disabled":"","yasr_review_type":""},"industry":[],"class_list":["post-70099","structure","type-structure","status-publish","has-post-thumbnail","hentry"],"acf":[],"yasr_visitor_votes":{"stars_attributes":{"read_only":false,"span_bottom":false},"number_of_votes":0,"sum_votes":0},"_links":{"self":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/structure\/70099","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/structure"}],"about":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/types\/structure"}],"author":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/users\/7"}],"up":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/structure\/441"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/media\/7586"}],"wp:attachment":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/media?parent=70099"}],"wp:term":[{"taxonomy":"industry","embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/industry?post=70099"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}