For more than 70 years, the customer needs of Bieri Hydraulic AG have been the focus of all products and new developments. Industry-specific solutions and profound knowledge in the field of micro and high-pressure hydraulics make Bieri Hydraulic AG internationally successful. Best quality and absolute reliability of the products are top priority. To be able to guarantee this, the assembly workplaces are already designed according to the specifications of Lean production.
With the further development of the axial piston pumps, the specification was to design the required assembly workstation in such a way that it would fit into the existing lean processes. For example, the new product was also to be produced in a one-piece flow in the future. Optimum assembly throughput with the shortest possible lead time was the specification at the start of the project. In addition, for quality assurance purposes, each axial piston pump was to undergo a function test, which would take approx. 4 minutes. The aim was to be able to complete the final assembly of a pump within this time frame. The challenge in this project was to be able to complete the assembly process absolutely error-free in 4 minutes in order to be able to test the function of the previously assembled axial piston pump at the same time.
The first approaches to a solution were quickly found during a Lean-Live workshop in Stein am Rhein at Phoenix Mecano Solutions AG. The advantage of this workshop was that the employees of Bieri Hydraulic AG were involved from the very beginning. All the individual components of the new axial piston pumps could also be included directly in the planning. Provisional work tables were assembled from cardboard boxes and standard modules and immediately fitted with the original components. This is called cardboard engineering. After extensive testing and continuous optimization, the result was a lean assembly island that enabled optimal work flow. Everything was fine-tuned for the precise assembly of the many different, small components of the axial piston pumps. Very important and valuable in this process were the inputs of the people who will also later work in the assembly. The creation of a table with a rotating device, which has seven presses, was able to fully optimize the workflow. This measure brought even more flexibility and resulted in an even more time-saving assembly.
This measure brought even more flexibility and resulted in even more time-saving assembly. With the help of lifting columns from Phoenix Mecano Solutions AG, the new assembly workstation was also made more ergonomic. With the correct height setting, it will be possible to carry out back-friendly assembly work in the future. However, it is not only the correct working height that enables optimum ergonomics, but also special tool holders that make it easier to grip and stow tools and ensure that the workplace is always clear and tidy. All this helps to maintain the health and satisfaction of all employees. Thanks to the consistent implementation of lean principles and the excellent cooperation between Bieri Hydraulic AG and Phoenix Mecano Solutions AG, it was possible to implement a project that guarantees a massive increase in productivity (up to 40%) with maximum process reliability and consistent top quality.
This measure brought even more flexibility and resulted in even more time-saving assembly. With the help of lifting columns from Phoenix Mecano Solutions AG, the new assembly workstation was also made more ergonomic. With the correct height setting, it will be possible to carry out back-friendly assembly work in the future. However, it is not only the correct working height that enables optimum ergonomics, but also special tool holders that make it easier to grip and stow tools and ensure that the workplace is always clear and tidy. All this helps to maintain the health and satisfaction of all employees. Thanks to the consistent implementation of lean principles and the excellent cooperation between Bieri Hydraulic AG and Phoenix Mecano Solutions AG, it was possible to implement a project that guarantees a massive increase in productivity (up to 40%) with maximum process reliability and consistent top quality.
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