Storage specification within the lean manufacturing environment

Many businesses now follow lean manufacturing principles, adopting new, more streamlined processes, which has affected the way storage systems are specified and used to ensure tools and components are safely stored. This includes the rise in the use of mobile storage, which can improve a business’ performance, simplify the working environment and help manage inventory. Here Clive Woodward, group managing director explains.

The term ‘lean’ was introduced to describe the production system developed by the Toyota company during the post World War II years and is based on the practice of achieving more with less resource. Today, the concept of lean is not just restricted to manufacturing but applies to an entire organisation, including the supply chain, product development and service.

As there is no recipe for manufacturing, with each company having its own way of working, then there is no set rule for how storage is integrated into the working environment. It is more a case of identifying the way the business specifically operates and looking for solutions that complement its processes and people.

For example, through flow process analysis, which involves mapping out how a production line should operate and looking at the current work stations, it is possible to balance the flow of work. It isn’t productive for one or two employees in a five station process to be taking longer to complete their part of the job, causing a bottleneck. By assessing the detail of the work for each person, work stations can then be designed around specific needs to improve efficiency and ensure a balance of work.

As well as being specified to fit operational workflows, storage should also help businesses to get the most out of the available floor space. This means not just looking at the physical sizes of drawers and cupboards, but how they are integrated. For example, where access is an issue, some storage manufacturers offer units with roller shutter doors, providing a viable option for users to access a cupboard’s contents where there isn’t sufficient room to open a door.

The right storage also increases a business' performance by reducing downtime and tool loss. Tools and components must be readily at hand and easily identifiable, contributing to the workforce’s efficiency - a fundamental lean principle. Mobile storage is growing in popularity for this reason as workers are not going off to locate tools for each task but instead can take the tools with them as they move around the plant.

In addition, it is not just the tools that can be moved along by workers on the job, but also materials and other consumables. For example, if an employee breaks a tool, blade, drill bit or anything else they may use in their toolbox, then instead of chasing the foreman for a hack saw blade, they can instead carry spares with them - again further aiding a worker’s efficiency.

When looking for mobile storage solutions such as trolleys, cabinets, benches and workstands, safety and stability must be considerations. Make sure castors are heavy duty and fitted with foot brakes so units can be safely kept stationary. Ensure mobile drawer systems incorporate safety trigger mechanisms, so they cannot accidentally open while in transit. To prevent units from tipping over if heavily loaded drawers are all opened at the same time, Bott’s units include a drawer blocking feature.

Correctly specified storage systems will also ensure efficient inventory management and visual management – another factor within lean manufacturing practices. Wall boards should feature silhouette shapes behind each tool hook, allowing the user to instantly see if a tool is missing. To also aid identification, it is becoming common practice for drawers to feature foam inserts with cut-outs.

Organised tool and spare parts storage means maintenance and production staff can ensure every component is accounted for. This is vital when working in areas such as food or medical lines, to ensure that no tools or small parts such as nuts and bolts can accidently enter food by being left within a production line, after maintenance has taken place. If this was to happen, the consequences can be costly and potentially disastrous to a company’s reputation.

Well planned storage systems can also lead to cost savings. Keeping items in defined locations makes it easy for staff to keep an eye on minimum and maximum stock levels so that new parts are only ordered when needed. Within the storage facilities, markers can be used to create a visual guide to help staff to identify when stock is running low. In addition, formal processes can instil employee discipline in retrieving parts from, and returning to, storage locations, ultimately saving inefficient ‘man miles’ by avoiding staff having to search for items and reducing their productivity.

It is possible to choose the right storage by working with a team of experts who will take the time to understand the business’ requirements and provide the right solution. Getting it right can result in efficient working practices, which positively affect a company’s bottom line and form part of lean manufacturing processes.