Kanban for metalworking company

Company
25 employees, production of marble cutting machines

Issue Addressed
Frequent shortage of parts in the head assembly line. Production halted, longer delivery times and higher management costs due to delays.
After a detailed analysis of the components and the frequency of use, we inserted a kanban cassette warehouse installed directly in the head assembly department.

Results
Reduction of missing parts during assembly: 100%
Reduction of times for supplier orders: 99%
Reduction of warehouse preparation times: 100%
Total savings comparable to a person €35,000.
One more person who can devote himself to assembly.

Vending Machine distributor for PPE equipment

Company
150 employees, mold making

Problem Addressed
Department Manager was wasting too much time on orders and personnel PPE management.

Solution and Results
Self-service PPE management with badge distribution
We have inserted a PPE vending machine. For each operational role, we established the appropriate PPEs: masks, gloves, shoes, work shirt, etc.
Then we created a profile and assigned a badge for autonomous collection. The consumption of each person is archived and in the event of an accident, the company is released from any liability on the PPEs.
To guarantee supply continuity, the vending machine is periodically replenished by ERI Service.
Man time saved is equal to ½ person, to which must be added the benefits of greater safety achieved.

Kanban solution for company 20 employees

Company
20 employees, manufacturing packaging machinery

Problem addressed
Each machine consists of around 1000 pieces. Highly customized products; with low production lots.
All the components were purchased individually on the basis of bills of materials.
The requested objective was to reduce supply times, management costs and avoid that production was slowed down or stopped due to missing parts.
We analyzed their bills of materials and highlighted some groups of items that could be grouped together as a single kit for assembly.
The kit, which also contains items from five different suppliers , now has a single code that the customer uses to order from Eri Service. For each kit we have also designed the packing box (an example in the photo).

Benefits
A single code instead of 20 for 5 different suppliers.
Nothing is ever missing: visual check on missing pieces.
Purchase costs unchanged.

Savings
The warehouse/orders/suppliers management has gone from 1000 codes to less than 200.
Before our intervention, the value of the process of purchasing the material of a single kit was of 400€, to which add 30 minutes of management.
Now the cost is 80€ and 3 minutes of management.
The company uses around 350 kits/year.

Assembly kit: from 300 items to 20

Company
100 employees, assembly of presses and shears

Problem to solve:
To build a press, it was necessary to purchase 300 items from 200 different suppliers.
This often led to problems in managing suppliers as well as missing pieces.

Solution
First of all we carried out a study of the machine model and we divided the material into assembly groups (kits) and created a box suitable for housing each component. The details are supplied directly by ERI Service already included in each box.
Inside each kit there are different articles of lathe, steel, aluminium, plastic, pneumatic articles, cutter articles, commercial articles , screws, etc. in the quantities necessary to assemble a group.
The company now has to order, from a single supplier, only 20 different assembly kits. A single code to manage during the purchase phase, a single shipment, a single warehouse management.
Thanks to this, from 200 items today the company orders 20 items to make a shear, eliminating the missing ones.
Savings : 2 people 70.000€. who can devote themselves to editing or something else.

Efficient warehouse management

Company
Automation, 8 people

Problem
Difficulty in fulfilling orders.

Analysis and solution
After in-depth analysis we took over the management of the complete warehouse part which was identified as being responsible for the problems.

Results
60% stock reduction, 40% reduction in missing parts during assembly, cleaning order, implementation of kanban inventory management for receiving pick-ups.

Savings
2 people €70,000 today with 2 more people in assembly they have increased turnover by €250,000.