LEAN-Live Workshop Helps to Increase Productivity by Up to 40%

For more than 70 years, Bieri Hydraulik AG has prioritized customer needs in all products and new developments. Industry-specific solutions and profound knowledge in the field of micro and high-pressure hydraulics have made Bieri Hydraulik AG internationally successful. Best quality and absolute reliability of the products are top priorities. To guarantee this, the assembly workplaces are designed according to the specifications of lean production.

With the further development of axial piston pumps, the requirement was to design the assembly workstation to integrate seamlessly into existing lean processes. The new product was also intended to be manufactured using a one-piece flow system. At the start of the project, the primary objective was to achieve optimal assembly throughput with the shortest possible lead time. Additionally, for quality assurance, each axial piston pump had to undergo a functional test lasting approximately four minutes. The goal was to complete the final assembly within this timeframe. The main challenge was ensuring that the entire assembly process could be carried out flawlessly within four minutes while simultaneously testing the function of the assembled pump.

The first approaches to a solution were quickly found during a Lean-Live workshop in Stein am Rhein at Phoenix Mecano. 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 were also 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 an optimal workflow. 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 would later work in the assembly. The creation of a table with a rotating device, which has seven presses, fully optimized 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 an even more time-saving assembly. With the help of lifting columns from Phoenix Mecano, 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, 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.