7 Core Benefits of Modular Applications in Lean Manufacturing

Further to our post Why modular solutions are the way forward, we take a look at some of the core benefits of modular systems and the features that can meet the changing dynamics of manufacturingprocesses and expansion in the workspace. Solutions which can “future proof” your business for advancements in process, technology and work styles, helping to meet quality management and completion time demands.

1. Minimise disruption

Approximately 80% of the solutions construction activity can be removed from your factory space as modular applications can be built in our controlled environment and delivered ready for installation –reducing waste and disruption and improving overall safety.  For an active manufacturing plant,reducing on-site activity is a tremendous advantage.  Improving quality management throughout the process with significantly less on-site activity and disturbance promotes sustainable, innovative, cost-effective and high quality solutions.

2. Integrate

Modular applications can be designed to fit in with the branding and aesthetics of existing modular units. Once assembled, they are virtually indistinguishable from their counterparts. This enables greater flexibility with more reuse options because modular solutions can be disassembled and reconfigured for new uses. This reduces demand for raw materials and minimises the amount of space required for storage.  Our modular solutions can also be colour coded to fit in with existing visual management and manufacturing good practice.


3. Reduce waste

size-7-rackTraditional manufacturing involves handling large pallets or containers and inventory batches, which is inherently wasteful. The use of modular parts supermarkets positioned at the line side to replenish stock frequently, with adaptable carts and trolleys designed to carry precise numbers of specific items to the line side, helps eliminate waste. Economy of scale for batch deliveries offers the super-efficiency of just-in-time line side replenishment. The adaptability and flexibility of modular applications supports continuous improvement because modifications can be made at any time to reduce wasteful processes.

4.  Add value

Efficient modular systems translate into cost savings. They can be installed over a matter of days, or built in a phased approach, which makes the installation process quicker and more efficient. The ability to reconfigure, relocate and adapt the system can save money and add value over the term of ownership, dependent upon the design and use. This enables manufacturers to save on space and expansion costs in the long-term by optimising the area needed for production and storage.

5. Promote efficiency

Modular solutions offer environmental benefits and sustainability.  For example, using modular andadaptable workstations, carts, trolleys and line side storage helps to create a highly efficient production environment where everything is designed to promote efficient and ergonomic working.  Workflows in the production process are seamless with the introduction of ergonomic workstations and trolleys built with our modular system.  Assembly processes can be executed at the right height for maximum safety and efficiency.

6. Reclaim workspace

Modular installations have the flexibility to reduce the footprint of the working area. They are also lighter and faster to implement than structures or solutions fabricated with traditional materials. Manufacturers can be more responsive to changing conditions and demands and so offer greater flexibility to their customers.

Modular solutions are easily reconfigured to reclaim valuable floor space to accommodate new technology or modify the ascetics of the work place.  They are flexible to meet changing layout needs and can be relocated and easily adapted to fit a new space.

7. Increase productivity

Changing dynamics in the working environment required by advances in technology, processes and increased demand have been shown to improve team productivity and employee retention. Modular storage and handling systems have become increasingly popular in supporting lean manufacturing. They allow space to be allocated based on function so that the working area is more efficient. This helps keep staff happier, more productive and less stressed.  Improved ergonomic work areas reduce operative movements while the introduction of “just-in-time” component supply can maximise efficiency and increase production.

Our design team can help you determine the best option for functional and agile solutions to suit both your production processes and your budget. Contact us for more information