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Worksmart Systems "Custom Lean initiatives Assembly Cell" Testimonial

Who We Are: Worksmart Systems Lean Manufacturing Experts Contact Us

Since 1988, Worksmart Systems has striven to provide innovative and cost effective cells for lean manufacturing and assembly. With products from medical to defense, electronics, transportation, consumer products and everything between, we have extensive track record in creating simple, cost effective solutions. Our areas of experience and expertise include assembly flow, lean manufacturing, ergonomics, parts handling, fixtures, parts presentation, shadow boards, packing, test, inspection, ESD control, error proofing and systems integration. To get an overview of our products please view the video on the right.

What We Do: Worksmart Systems Lean Assembly Cells and Ergonomic Workstations Contact Us

Worksmart System has 1000's of successful Lean Assembly cells and Ergonomic Workstations installations. The modularity of our system encourages experimentation and continuous improvement. The following videos cover our best practice methods for design of Lean Assembly Cells and Ergonomic Assembly Workstations. An additional video covers 6 Steps for Value Stream Mapping the Assembly Process.

10 Rules For Successful Lean Assembly Cell Design

After designing and building proven and successful assembly and lean manufacturing cells for over three decades, we have put together the commonsense rules that run through our cell concepts. Whether you are building a few or hundreds of units per shift, they will provide benefit, and pay dividends.

5 Steps for Ergonomic Workstation Design

Best practices require sitting or standing height workstations tailored to the operators and task to avoid injury and increase efficiency.

6 Steps to Value Stream Map an Assembly Process

A good approach toward creating a Lean Assembly Cell is to Value Stream map the process.

In this video,
Worksmart Systems lays out the course.

How We Do It: Worksmart Systems Case Study Videos Contact Us

Worksmart Systems doesn't just talk Lean Manufacturing, we help your team create a Lean Assembly Cell or Ergonomic Workstations to your specifications. Additionally we can provide systems integration to enhance the cell’s operation.

Please take a look at some of our installations depicted in the Case Study videos.

Synchronous Flow Lean Assembly Cell

An eight position cell with powered synchronous low and height adjustable, ESD workstations

1. Fleximate Transport Line - Straight ESD Cell with Single Unit Flow, and on Line Test

This 100 foot long cell is an example of a straight ESD cell with single unit flow and on line test for a high volume electro-mechanical product. Other features include custom fixtures, a powered empty cart return, lift and lowering elevators at each end of the cell and mobile parts flowracks.

2. Fleximate Transport Line - Custom pallet cell for a 350# product with a 30" x 39" foot print. 11 Positions in a 100 foot long line

This cell features single piece production with improved ergonomics, supermarket parts presentation, tool handling, on line test and many other enhancements. Other options include, height adjustability, fixturing, error proofing, elevators and automated empty pallet return.

3. Fleximate Transport Line - Oval Configuration with Custom Trunion Fixture

This cell produces a heavy mechanical product. Our fixturing provided manipulation and rotation in two planes which combined with a optimized track height provided efficient worker ergonomics and simple product transfer.

4. Fleximate Transport Line - "S" Configured Cells in a Clean Room Environment

Two long cells for a 250# product. The unique cart design enabled operators to on line inspect for QC. Production flow was a combination of free and powered conveyance.

5. Fleximate Transport Line - Lean Assembly Cell Straight Line

Two custom Fleximate cells featuring unique overhead return of empty pallets due to unique fixturing. Cart tops featured rotation for this high volume automotive application.

6. Fleximate Transport Line - Clean Room Oval Configured Cell with In Line Oven Integration

This application includes a progressive flow through a low temperature oven in a clean room. Also featured is a post cure powered, section for cool down, Custom workstations were integrated into the line to minimize handling of the heavy product and fixture.

7. Fleximate Transport Line - Oval Cell Configuration with Unique Fixturing

This complex mechanical assembly required some fresh thinking for multi access assembly. Custom work surfaces assisted in worker ergonomics and assembly productivity.

8. Fleximate Transport Line - Oval Configuration for a Heavy Product with unique Parts Kitting Capability

This cell featured a re-manufactured product which required that all reused components remain together. We provided a means of keeping the family of parts together with the product housing.

9. Fleximate Transport Line - Mixed Model Cell in Straight Configuration with Supermarket Parts Presentation

On line supermarket parts presentation supporting a high volume, high mix production schedule.

10. Fleximate Pallet Slide Lines - Twin Parallel Straight Cells for a 400# Product

Two sliding pallet cells featuring custom tool presentation, poke yoke, universal fixturing details, and custom power, signal and air distribution. Automated pallet return with elevators and ESD control were other design criteria.

11. Fleximate Transport Line - Mixed Model, Single Piece Flow in a Straight Line

In this application, fixturing and parts presentation was created to produce completely different products. Sub assembly stations produced at point of use with quick change over capability to support mixed model flow. An overhead lift with a lifting yoke made packaging a safe, single operator operation.

12. Fleximate Pallet Slide Line - Short Takt Time, Mixed Model Production in a Straight Line

This cell was designed to handle a wide range of product sizes by incorporating some unique controls and varied parts presentation.

13. Fleximate Pallet Slide Line - Low Effort Sllde Line for a Mechanical Product Family weighing up to 900#

A low volume product that was transitioned from batch to progressive assembly. Unique challenges included height adjustability, multi product, quick change, adapter plates and inline leak testing.

14. Fleximate Transport Line - "L" Configured Cell with Integrated Ergonomic Product Manipulator

Electro mechanical assembly cell with fixturing challenges. Also included was a product tilt assist that transitioned the process from an unsafe, two operator lift to a semi automated, single operator, ergonomic operation.

15. Fleximate Transport Line - High Torque Production in a Straight Line with A Turnstyle feeding Two Test Bays

This cell successfully transitioned a high mix, low volume production from batch to single piece, progressive production. The design wish list included the ability to handle high torque assembly, dual test bays with out production constrictions and an anti-tip safety feature.

16. Fleximate Transport Line - Straight Cell Incorporating Ergonomic Fixturing to assist Assembly

An in depth assembly examination yielded some beneficial fixture considerations. An end of cell, lifting arrangement made packaging a safe, single operator process.

17. Fleximate Transport Line - Straight Cell with Mechanical Assist Product Manipulation

This mature product was transitioning to a single piece flow with standard work procedures. We incorporated ergonomic fixtures and a high pressure test process in line and yielded high productivity.

18. Fleximate Slide Line - Transition from Batch Production for a Heavy Product Family. Cruciform Layout

This cell featured a stainless steel fixture plate rolling on custom roller tracks with multiple safety features for up to a 1200# product. The high mix, low volume product line required height adjustability, low effort, production flow, and multiple test bays. A powered turntable allowed production to flow, uninterrupted, into one of three test positions.

19. Fleximate Transport Line - A "U" configured Cell with Stringent ESD Control Requirements

Multiple work height stations, high performance ESD control and integration of a UV cure tunnel were just a few of the requirements for this electronic product's production.

20. 1-3 Operator "U" Configured ,Mixed Model Flex cell With Lift Assist

This cell features universal fixturing for multiple models, product lift assist by a single operator and the ability to be staffed by 1 to three operators. A shuttle system provided a simple method for empty fixture and cart return from the end of the cell to the head.

21. ESD Assembly Cell - with Height Adjustable Stations and Redundant Test Bays

ESD Assembly Cell 2020 d1

22. Two Position Mechanical Assembly With Poka-Yoke

A flexible cell incorporating a custom press, universal fixturing and poka-yoke.

23. 4 Station Cell featuring Poka Yoke Kitting and Enhanced Ergonomics

This project involved the mixed model assembly of a heavy product. Objectives included: error proofing, improved production flow, enhanced assembly ergonomics and maximizing space utilization.

24. Worksmart's Multi Bay Test and High Pot Cell

A constriction free, multi-unit, one piece flow, test cell used for high mix production flow.

25. Compact "U" Shaped High Mix Electronic Assembly Cell

See a "U" configured assembly cell with ESD protection that allows the team to work "one ,one down" depending on product mix and production volume. Right sizing delivers maximum space utilization in tight quarters. Powered empty cart return with elevators at each end of the line eliminated operators having to deal with empty carts.