Under the guidance of Production Supervisor Flemming Pedersen, the production hall has evolved from traditional methods to a streamlined Lean approach, leading to an outstanding 50% efficiency improvement. Advanced safety protocols and sustainable practices further bolster the success of this transformation.
Reinventing Intralogistics and Enhancing Safety
“Our entire production process has been transformed,” says Flemming. A core change is the adoption of a one-way flow for goods — from their entry point to the exit. This significant adjustment has been made possible by constructing a hole in the wall at the opposite end of the building. Goods now enter for assembly from one side, and the fully assembled lifting tables exit from the other side, moving onto an automatic conveyor system for outbound delivery. This single-stream flow has been a key factor in improving efficiency and safety, saving time and reducing risks. This, however, is only one of many examples of the extensive changes we’ve made.
Safety improvements are noticeable everywhere. The addition of a safety railing helps guide personnel away from the loading area, reducing potential accidents between forklifts and workers. Additional modifications, like maintaining all parts and racks at a uniform height of 1.50 meters, ensure a clear line of sight across the shop floor, promoting better workflow and early detection of potential bottlenecks. Furthermore, it enhances safety by making any unlikely accident immediately visible.
Moreover, we’ve revamped every single area of the shop floor to enhance safety. In workstations that previously had a multitude of electrical wires leading to the workplace and testing equipment, we now have a single cable. This significantly reduces the risk of tripping or falling over wires, simplifying the workspace and minimizing hazards.
Embracing Lean Principles for Efficiency, Quality, and Sustainability
The adoption of Lean principles has been instrumental in driving efficiency and quality improvements. A prime example is the implementation of the kanban system, with color-coded boxes and distinct barcodes for each type of bolt and screw, eliminating time wasted on restocking.
Flemming’s dedication to sustainability is clearly demonstrated by the installation of energy-efficient lighting, reducing power consumption by an impressive 90%. “We need to take care of both our employees and the world’s resources,” he declares.
However, it’s not just about the physical changes. “The real shift is in the mindset. To truly benefit from Lean, you have to live and breathe its principles,” Flemming emphasizes. “We’ve made significant strides, and there’s much more on the horizon.” A crucial component of this success is that the changes originate from within; our own team devised these improvements. They are not quick fixes from an external consultant; these changes have sprung from the minds of our own team members. We don’t just learn Lean — we live it!