FALL 2022

28 THE DISTRIBUTOR’S

28 THE DISTRIBUTOR’S LINK Bruno Marbacher Bruno Marbacher earned his mechanical engineering degree in Switzerland, he also holds a business degree. He started out as a tool and die maker (poly-mechanic) and over the years he has held various management positions in quality and engineering. During his time in America he has developed and given numerous seminars on topics related to the proper use of mechanical fasteners and machine elements, and assists engineers in solving fastening/assembly issues. His has groomed and directed many young engineers in fastening/assembly technology. He now offers his 40 years of experience through writing and lecturing. ASSEMBLY LINE WALKS TO SEARCH FOR COST SAVINGS OPPORTUNITIES Dear Reader, In this editorial, we will address how one can go about conducting a cost savings line walk. We also include some examples from actual line walk reports. All suggestions made in this report are in support of Lean Manufacturing, using the principles and strategies of Lean Manufacturing. Here is what is typically being addressed in a line walk: ¤ Simplifications of the assembly process (do the job with fewer tools) ¤ Elimination of SKU’s (reduce number of stock-keeping units) ¤ Reduction of waste (material and time) ¤ Streamlining assembly (improving flow of work) ¤ Reduction of material cost ¤ Focusing on potentials for assembly slow downs All in all, we are looking for opportunities to make the overall production simpler and more cost efficient. Specifically, we were looking for things that could be implemented without major design changes. We included small sub-assemblies, currently carried off the main assembly line. Those subassemblies can typically be outsourced to TECHNICAL ARTICLE places that specialize in that sort of things. Many distributors work with facilities that can do this kind of work. Benefits of Consolidation They typically result in: ¤ Reduced requests for quotes ¤ Reduced order placements ¤ Lower unit prices ¤ Lower location set up cost ¤ Less re-stocking trips (fills) ¤ Improved assembly efficiency ¤ Fewer stocking bins ¤ Fewer opportunities for stock outs ¤ Fewer tools ¤ Less assembly stations ¤ Simplified inventory management Line Walks Cost Analysis Process Opening Meeting ¤ Short overview of other cost analyzes conducted elsewhere ¤ Discuss customer’s expectations ¤ The customer engineers brief about product ¤ Review fastener use etc. Line Walk ¤ Get acquainted with product (end of the line) ¤ Conduct analysis on final product ¤ Get to the beginning of the line and start line walk analysis ¤ Collect all data and information CONTINUED ON PAGE 128