Systematic organisation: How Schleuniger makes assembly more efficient
At its site in Thun, Schleuniger AG develops and manufactures innovative solutions for wire processing and supplies customers around the world.
Anyone entering Schleuniger’s assembly hall will quickly notice that every tool has its designated place. Open tool trolleys filled with all kinds of equipment are nowhere to be seen. Instead, clearly structured workstations, standardised processes and well-designed organisation systems define the working environment.
This approach is no coincidence. Schleuniger AG has been actively engaged in Lean Management and the continuous improvement of its processes for many years. The company develops and manufactures machines for the wire processing industry and is part of the globally operating Komax Group. Schleuniger solutions are used wherever wires and cables need to be automatically cut, stripped, processed or assembled into complex wire harnesses.
With subsidiaries and sales companies around the globe, Schleuniger has a strong international presence. At the same time, the company continuously develops its internal processes at its Swiss site to make production even more efficient.
Lean starts at the workstation
For Michael Zbinden, Group Leader Operational Excellence at Schleuniger, Lean does not start with major projects, but in the everyday working environment. Continuous process improvement has been part of Schleuniger’s corporate culture for many years. At its core is the Lean philosophy, with the aim of making workflows as simple, transparent and efficient as possible.
One important step was the consistent standardisation of assembly workstations. While tool trolleys used to be equipped with a wide range of different tools, the focus today is on providing employees with exactly the tools and equipment they need for each individual work step.
Michael Zbinden, Group Leader Operational Excellence at Schleuniger AG, presents one of the foam inserts developed together with Brütsch/Rüegger Tools for standardised tool organisation.
This approach initially led to the development of simple tool boards. However, it soon became clear that a more professional solution was required. The desire for greater organisation and standardised workstations first resulted in in-house solutions. Foam inserts were cut internally and various materials were tested. In everyday use, however, it quickly became apparent that an industrially manufactured solution was required for sustainable and professional use.
A look inside assembly at Schleuniger AG: defined tool locations and standardised workstations support structured and efficient workflows.
Better overview, less time spent searching
While looking for a suitable partner, Schleuniger found Brütsch/Rüegger Tools. Together, the companies developed customised foam inserts precisely tailored to the requirements of the assembly operation.
The close partnership was particularly appreciated:
“We already had specific ideas. Together with Brütsch/Rüegger Tools, however, we were able to develop the solutions significantly further.”
Today, the inserts accommodate much more than standard tools. Special gauges, fixtures and custom tools have also been integrated. This creates a workstation where employees can see at a glance which tools are available and whether anything is missing.
The benefits are immediately noticeable in everyday work. Tools no longer need to be searched for, damage is identified more quickly and the workstation remains organised over the long term. The foam inserts provide clearly defined locations for each tool and make the entire set easy to check at a glance. Missing tools are immediately noticeable, while the system also promotes organisation and careful handling of equipment in everyday use.
Organisation creates efficiency
In addition to improving visibility, the way people work has also changed. Tools are located exactly where they are needed. Frequently used equipment is particularly easy to access, while tools used less often are deliberately positioned further back.
This “Best Place” philosophy enables employees to work efficiently while avoiding unnecessary movement.
Clear structures at the workstation: foam inserts from Brütsch/Rüegger Tools help employees find tools quickly and ensure that all required equipment is available at all times.
At the same time, standardised workstations help employees consistently follow defined processes and enable new employees to become familiar with their tasks more quickly. In a sense, the arrangement of the tools guides employees through the workflow and provides additional reliability in day-to-day operations.
Next steps already in planning
For Schleuniger, however, optimising workstations is just one element of a broader development programme. The company is already working with Brütsch/Rüegger Tools on further projects.
The main focus is on the management of consumables and the further automation of procurement processes. Solutions currently being evaluated include dispensing systems for consumables as well as digital solutions that can largely automate ordering and replenishment processes.
Schleuniger AG’s continuous improvements in workstation design are clearly reflected throughout its assembly operation.
Conclusion
Schleuniger clearly demonstrates that Lean Management is about more than methods and KPIs. Often, it is the seemingly small improvements in everyday work that make a tangible difference.
The customised foam inserts provide a better overview, reduce search times and promote a structured way of working. At the same time, they provide the foundation for further optimisation in material supply, workstation design and process automation.
As Michael Zbinden sums it up: