Consultancy

LEAN workstation systems

RK LEAN Solution workstations – we plan customised systems for our customers

Lean management – RK is your partner for the implementation of individual workstation systems

Individual Lean workstation systems with the RK modular design

Lean Production – Ergonomic workstation design in production

Lean management, Lean production and Kaizen are concepts encountered with increasing frequency when it comes to optimising production processes, reducing (and ideally eliminating) waste, and striving for continuous incremental improvement. These are issues on which companies will have to increasingly focus in future if they are to remain competitive. RK Rose+Krieger has engaged with lean management for a considerable time now and, thanks to the diversity and versatility of our products, we are able to offer a wide range of individual solutions which can be tailored precisely to your requirements.

"When designing a workstation, the aim is to adapt the working conditions to the human, and not for the human to have to adapt to the given working conditions".

Ergonomics in production/manufacturing is largely viewed as a major cost factor. This is a misconception. The opposite is in fact true: ergonomic working has a lot of benefits. The positive effect on the effectiveness, health and motivation of employees is a notable example. In times in which there is a lack of qualified specialists it is important not to underestimate these points.
The aim of ergonomic workstation design should be to guarantee that the employee has a balanced workload. Because neither being overtaxed nor underchallenged is conducive to a pleasant working atmosphere. But this is the basis for a low burden on health and optimum work results. As a result, a considerable contribution to the creation of value and the competitiveness of the company.
 

Catalogue, RK LEAN Solution
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LEAN workstations are ergonomically designed and tailored individually to the process.

LEAN workstations are ergonomically designed and tailored individually to the process.

Modular LEAN workstations – ergonomic, tailored ideally to the process and later adjustments are easy to implement

Modular workstation systems with a number of components which can be freely combined with each other have clear benefits compared to standard workbenches or tables which have been designed specifically for one task. For example, when changing models or introducing new technology, the modular construction of the RK workbench can be modified without any problems. The modular system from RK Rose+Krieger provides a number of options for upgrading or modifying the system.
An optimum working height setting is without doubt one of the basics when it comes to workstation design, especially if different employees work at the same workbench. Thanks to electric lifting columns this height adjustment can be made simply and conveniently. As well as being able to make the optimum working height setting, the employee can also alternate between working when seated or when standing. This promotes effective, fatigue-free and healthy working.


Actively involving employees in LEAN conversions
When an assembly workstation is to be converted to a modern Lean workstation, it makes sense to involve the employees working there in the planning early on. Nobody knows the processes better or can assess where problems and delays frequently occur. They provide valuable feedback on detailed improvements which in turn can lead to further increases in efficiency. The worker can contribute his/her own ideas which in turn improves acceptance of the coming changes considerably.

 
Comparison of conventional manufacturing with one-piece flow production types

Comparison of conventional manufacturing with one-piece flow production types

One piece flow – the workplace is optimised for the production process

What does one-piece flow mean?
The one-piece flow principle is also referred to as employee-centred workflow. With conventional conveyor belt manufacturing the same task is always carried out at a fixed station. For example, fifty gear units are manufactured bit by bit in individual steps. A lot of time passes by in which the company does not earn any money and any production defects are not noticed until very late when a large number of gear units have already been completed. The rectification work on the 50 products is very time-consuming and costly.
With one-piece flow on the other hand the employee accompanies the workpiece through the individual assembly/processing steps and has to have a command of all work processes. The idea behind this: to reduce lapses in concentration caused by monotony and to increase motivation by way of variety. The quality/functional check is performed after every single final product and this is much earlier than the sale.

Characteristics of a one-piece flow workstation:

  • Quicker quality feedback
  • More flexible response to customers' needs
  • Less space required
  • Reduction in inventory and intermediate storage
  • Shorter processing times
  • Increased productivity
  • Interesting working environment
  • Reduction in overall costs
  • Ergonomic workplace
 
Custom foam inserts make for a tidy arrangement of the tools in the workstation

Custom foam inserts make for a tidy arrangement of the tools in the workstation

LEAN production – the 5S method is more than just tidying up

The 5S method is one of many approaches which have a positive influence on workstation design. However, it generally forms the basis for further activities and already involves some very practical effects itself. The tidy and clean workstation reduces search times and the risk of work accidents is reduced, for example.

The 5S method is the most important basic method of Lean management. It allows for efficiency, quality, tidiness, cleanliness and safety to be improved simultaneously. The 5 terms, translated from Japanese, stand for:

  • Sort – seiri
  • Set in order – seiton
  • Shine – seiso
  • Standardise – seiketsu
  • Self-discipline – shitsuke

The aim of the 5S method is to only have those objects at the workstation which are genuinely required. In the process, there is precisely one clearly defined station for each piece of working equipment and the sequences at the workstation are standardised. The employee is instructed to maintain and improve the condition.

 
Our service – expert consultation also available on-site

Service is our top priority

Our service – expert consultation also available on-site

If you want to focus your resources on other tasks and are looking for an expert partner you can rely on... our specialists will work closely with you to develop tailor-made solutions.

  • Field service – on-site consultation also available
  • Our Key Account managers and sales consultants are happy to visit you on site and help you draw up practical solutions.
  • Just make a sketch of your requirements
  • Workshop – definition of the required components
  • Our product specialists will devise a solution for you
  • Implementation and delivery.
    We can deliver your turnkey solution or assemble and commission it for you on site.



The LEAN workstation systems can be upgraded with a wide range of assistance systems:
 

Pick to light workstation
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Poka-yoke workstation
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Workstation with camera-based assistance system
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Do you have any other questions?

We will be happy to advise you on any specific questions you have about our products to help you find the right solution for your application.
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