Motor manufacturer moves to one-piece flow

By Staff -- Modern Materials Handling, 9/15/1999

With much of its productivity based on fluctuating consumer needs, MTS Automation, Custom Servo Motors (CSM) was looking for a way to streamline its manufacturing process. Transition from batch assembly to progressive flow assembly proved to be the solution.

Based in New Ulm, Minn., CSM manufactures a line of brushless servo motors, amplifiers, and motion controllers. Almost 40% of CSM's business is catalog product built for stock. The remaining 60% is custom product built to order. CSM reports 10-15% growth per year.

Product was batch built with 10 operators assembling units from start to finish on traditional workbenches. Production rates were inconsistent, and daily output ranged from 20 to 100 motors per day. The change to progressive flow assembly offered flexibility while reducing the amount of on-hand inventory and eliminating product handling.

Prior attempts to manufacture on conveyors were unsuccessful because of an inherent inflexibility and lack of features. Management knew it needed a work cell that combined the best features of an ergonomic workstation and a conveyor. CSM was introduced to an innovative, low cost assembly system, the FlexiMate Transport Line, that allowed for the transition to one-piece flow, and offered the flexibility needed.

This hybrid workstation/conveyance system, transports work-in-process on non-powered carts. Work is performed directly on the cart's top, and manually passed to the next workstation. Stations are connected to one another by a track system, allowing for the addition or removal of workstations with only four screws.

Since the system is constructed of round aluminum tube, individual workstations are infinitely adjustable. Operators can make modifications to their workstations with only a 3/16 in. hex key. This feature allows fine tuning parts presentation.

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