Process Analysis and Planning
DSI engineers are all well versed and use current WCM ergonomic standards that focus on the operator when designing workstations, material presentation and tooling that the operators interact with. Acceptable weight limits for lifting and placing, as well as the correct presentation of lineside material are all considered.
- Lineside Displays
Design Systems' experienced team of Manufacturing Engineers will provide processing support to assist in the development of station line display layouts as a part of the analysis of your complete internal logistics operation. By using the concepts of the Toyota Production Systems (TPS), Lean Manufacturing, Just in Time (JIT) inventory management, WCM, and non-value added analysis we will assure the evaluation of every aspect that would affect the line display portion. "Circle of Work" or Material Delivery plan is required to assure the right quantity of material is displayed at the right time, and in the correct way.
It is essential to determine how one variable impacts the next step in the circle so that the optimal layout for line side is made for people who is delivering the material, as well as for people who is using the material for their operations, enhancing the use of space and using the right equipment for the parts, etc.
- Work Instructions
The key to standardized work is empowering the worker. DSI has created very simple to use forms which any worker can easily learn, understand, and maintain once we are gone. We have customized forms to fulfill the requirements for stop stations, job shop applications, and for typical assembly line process work.
- Station Readiness
Design Systems team of manufacturing engineers will provide assistance with identifying and implementing production launch requirements for new and revised production operations to assure a successful launch at the station level.
The team will lead station set up, station organization and overall launch readiness activities to ensure that your new product is processed as planned with the quality you expect.
No detail will be missed by meticulously planning and preparing each and every operator station to support production at a high rate of efficiency and safety.
- Poka-Yoke Processing
For preventing operator error when carrying out any production activity. It is a way to build quality into the process and error proof the line. Methods of in-process validation include scanning a barcode on the part to confirm it is the correct part, using a light bar that displays how many of the part is needed for each pigeon hole.
Advantages to using the Poka-Yoke method as opposed to a quality check station is that no training program is required, inspection stations' labor and material costs are eliminated, operators are not performing repetitive activities, it promotes creativity and value added activities, and there is an immediate recognition of error which eliminates more involved rework further down the line.