Manufacturer Improves Quality, Productivity While Reducing Workstation Clutter

SITUATION

Jabil Advanced Mechanical Solutions, a Mexico-based manufacturer of metal fabrications and machine assemblies, was looking for a way to standardize its fabrication and assembly processes to ensure high levels of quality no matter which operator was working on the part.

Established in 2010, the company produces enclosures, racking, weldments, and large assemblies for industries such as transportation, health care, telecommunications, industrial, and the self-serve retail market. Welding, bending, machining, painting, and assembly all take place in its facility.

Because of its toehold in many industries, the company not only creates many different parts, it also works with several materials. As in any shop, quality and productivity need to remain high, so the company went looking for a 21st-century answer.

“The operator’s station, whether it was machining, welding, bending, or assembly was always full of part drawings and instructions,” explained Engineering Manager Marco Guzman. “They would constantly be flipping pages while working to make sure they were at the right step in the process and that the quality was where we needed it to be.”

The company needed a system that would help its production and assembly workers perform the correct task at the correct time.

RESOLUTION

In late 2012 the company was introduced to Visual Knowledge Share (VKS), Chateauguay, Que., a visual work instruction system.

VKS is a computer touchscreen installed at a workstation that enables the worker to view the operation on screen.

“As a part arrives at a station, a worker can view a real picture of the part and the instructions for the work that needs done,” said Guzman. “In complex bending operations at the press brake, or during construction of a difficult assembly, these visual aids help guide our people through their tasks. It helps take pressure off of them and ensures that operations are performed in the correct order.”

The system not only guides workers through the tasks; it also monitors the amount of time the process requires and allows for changes in the process from designers and engineers to be made company wide.

“If we need to make a change to a part, we can make the change in the system and an alert will pop up at each station that is making that part. Otherwise we would have to visit each station and update the drawings individually,” said Guzman. “This reduces the time it takes to make the change and also makes sure that no station or worker is missed.”

This technology reduces confusion, added Guzman because because an employee can see exactly what is required of him, and it can reduce defects to practically zero.

Cross training and the training of new staff also is made easier.

“Combining clear visual and written instructions, while still giving the worker access to schematics on the screen, makes it much easier for us to give someone new tasks,” said Guzman. “This reduces the time it takes to train someone on a new machine or process, which saves the company money, especially if it’s a new hire.”

www.jabil.com

www.vksapp.com