Tackle the Seven Wastes of Lean Weighing Improves Production · Tackle the Seven Wastes of Lean...

16NewsIndustrial Weighing and Measuring

Manufacturing

duction process. Wastes, such as over-production, product defects and unnec-essary transportation time stem from inefficient and disharmonious produc-tion processes.

Scales and balances not only fulfill their weighing tasks within the process, but they also contribute to process improve-ments on the shop floor. Let’s take an in-depth look at the wastes of lean and how weighing can prevent them.

Please find more information about “The 7 Wastes of Lean” on page 2 – 3.

When manufacturing hundreds of parts and components, the cost of production defines your competitiveness and your success with customers. While parts and components differ among factories where they are produced, the typical wastes found in discrete manufacturing envi-ronments do not. With weighing, you can eliminate the root causes of the common sources of waste.

The definition of Lean Manufacturing is a process-management philosophy de-rived mostly from the Toyota Produc-tion System. It identifies seven wastes to be avoided in a modern, efficient pro-

Tackle the Seven Wastes of LeanWeighing Improves Production

We all have been preached the power of Lean Manufacturing – high-quality products,

more punctual deliveries and a significant reduction in stock inventories. Sounds

great, right? Well, it is, if your business can manage to address the seven wastes of

Lean Manufacturing.

32 METTLER TOLEDO Manufacturing News 16 METTLER TOLEDO Manufacturing News 16

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Publisher / ProductionMettler-Toledo GmbHIndustrial DivisionHeuwinkelstrasseCH-8606 NänikonSwitzerland

Subject to technical changes© 09/2016 Mettler-Toledo GmbH

1 Transport time

Transporting products during production is a cost that adds no value to the product. Save time in warehousing and production with mobile counting. Simply put compact scales on trollies and transmit data wirelessly. That facilitates a 98 percent reduction in walking. To weigh bigger loads, use a pallet truck scale to move and weigh goods at the same time.

Further InformationTo make sure you use the right equipment for your appli-

cation please consult our Good Weighing Practice team: www.mt.com/gwp-rec-counting-ma

For more Information about Lean Manufacturing visit: www.mt.com/ind-lean-manufacturing-ma

7 Defects and rework

Checking quality using scales is a simple method to avoid costly recalls due to damaged or incomplete products. Place a product on a scale or weigh module and check for completeness against a preset target. With that, you can identify out-of-spec products quickly and reliably in manual or

automated processes.

6 Overproduction

Producing too many parts and components result in high storage costs. Weigh production output at the end of your production line

to know the right time to stop producing. That not only saves you money, but it also allows you to verify stock quantities more easily. With scale-assisted parts counting, you can also im-prove your intra-logistics and supply your shop-floor work-stations with the exact material counts.

What works for your processes can satisfy your customers as well. Use scale-assisted packing to ensure precise pack-age counts. Fulfill your shipments while the box is placed on a scale to eliminate under- or over-filling.

5 Inappropriate processing

Using the right weighing equipment for your processes is im-portant for product quality. Using the wrong weighing equipment

can lead to poor quality, product defects and rework. This results in significant monetary loss over time. Scales have to fit your applica-

tion, tolerances and work environment. Select the right scale for your pro-duction with GWP®.

3 Unnecessary motion Unnecessary motion includes operator movements that are not related or required for the processing of a product. That kind of motion not only sacrifices your production efficiency, but also results in increased labor costs, injuries and acci-dents. To avoid those issues, scales can be installed and termi-nals can be mounted in various ways to fit the operator and workplace for more ergonomic motion.

2 Unnecessary inventory

Reduce your inventory and make your warehouse lean. Weigh deliveries from suppliers right at the receiving department. The weighing data gives you an overview about date, time and quantity of goods that entered your facility. You can keep track of your stock items by count-ing them when they enter the warehouse or upon pro-duction. Count smallest quantities of high value goods with high-precision counting scales or verify complete batches with floor- or pallet scales.

4 Waiting

Whenever products are not moving or being processed, the waste of waiting occurs. We are dedicated to helping you speed-up weigh-ing tasks for high throughput even in manual assembly. Therefore, our scales are equipped with the colorWeight® display function that indi-cates weighing results using a simple color code. It increases handling speed by 30 percent and reduces misreadings to zero.

You may also have to wait for scale data to upload. To ensure weighing data gets to every scale on the shop floor as quickly as possible, we rec-ommend using databICS software and WLAN for easy data management and fast distribution.

7 Wastes of Lean

Improve your parts production with weighing instruments

Eliminate your

above target ok below target


Hel

icop

ter B

alan

cing

Four years in the making, a lightweight, turbine-powered helicopter featuring a carbon cell was developed by MarencoSwisshelicopter AG. The Marenco Swiss-helicopter SKYe SH09 features a state-of-

the-art glass cockpit, outstanding flight performance and low operating costs.

The center of gravity mattersThe center of gravity affects the stress ex-

erted on wearing parts, such as the rotor head. Therefore, it has a major impact on the helicopter’s operating costs. In addi-tion, it considerably influences the steer-ing properties and fuel consumption.

Perfect Balance in the SkyWeighing Determines Center of Gravity

If you know anything about helicopters, you know that the center of gravity

is critical, not only to safety but also to the helicopter’s operating costs.

High-precision weigh modules handle this tough task with ease, keeping

passengers safe and costs at a minimum.

Switzerland-based Marenco Swiss-he-licopter AG wanted to use cutting-edge weighing technology to develop a porta-ble system for determining the helicop-ter’s center of gravity.

A unique solutionBy introducing a customized solution, we helped to enable precise calculation of the center of gravity of this prototype. A weighing system, featuring four SWB505 MultiMount™ weighing modules con-nected to an IND890 high-end terminal, measure the weight at four points under the helicopter’s skids.

The entire application was brought to life on the graphics-capable IND890 terminal with touchscreen, enabling operation that is simple, convenient and fast. To ensure precise taring for the helicopter, the cen-ter of gravity is consistently calculated in both the X and Y directions, and the dis-tance to the nearest weighing point is rep-resented visually by crosshairs.

www.mt.com/ind-multimount-ma

www.mt.com/Ind890-ma Freely programmable foryour custom applicationIND890 program can be customized for appli-

cations ranging from workflows to data inte-

gration with enterprise-level software.

It features:

• Human-machine interface and application

customization

• MS .NET language support

• Display capabilities up to 19” color TFT

• SQL database exchange

www.mt.com/ind890-ma

The IND890 display shows a custom application.

The Helicopter is mounted on METTLER TOLEDO’s SWB505 MultiMount Weigh Modules.

SWB505 MultiMount™


Calib

ratio

n Se

rvic

e Eliminate Incorrect Counting RiskCalibration Prevents Financial Losses

Are you sure your counting scales are accurate? A scale’s accuracy can vary over time.

Maintain consistent accuracy with calibration services by our trained technicians who

understand your application and provide certificates and proof of traceability.

Heavy use and external factors can lower a scale’s accuracy over time. At a certain point, you cannot entirely be sure that you are still weighing within your pro-cess tolerances.

Calibration prevents miscountingDo you wonder if you received the exact number of parts from your supplier or if you sent intact packages to your customers?

Stop unnecessary process variations and miscounting with regular calibration.

Services and certificates Calibration ensures quality and compli-

ance with unmatched ease and consis-tency. Whether you check bulk goods or small kits, or verify sub-assemblies or product packages, calibration service is crucial to keeping your scales running at their best.

If you do not have a supplier that com-pletely understands your instruments and application, you may not receive the nec-essary services for all of your scales.

A METTLER TOLEDO service technician ensures you don’t have to worry about miscounting, failing an audit or basing your quality assurance on incorrect re-

sults. We offer a broad portfolio of cali-bration certificate types to fit your needs.

But how regularly should you calibrate your equipment? With limited guidance and many scales on the shop floor, keep-ing your equipment accurate with cal-ibration depends on the factory’s turn-around schedule. The question is: is this frequently enough for my process toler-ances or my desired counting accuracy?

Automotive supplier industry The automotive industry has higher re-quirements regarding calibration than others in the manufacturing industry. The

industry’s ISO16949 certification require-ments demand that measuring equipment should be calibrated or verified at specific intervals or prior to use. However, it does not indicate the fixed interval.

Intervals depend on individual circumstancesThe actual interval of calibration depends on how critical the weighing process is in your production. Manufacturers have to define how much the money loss or the reputational damage would be if the

Calibration and Certification Packages

Calibrate Basic Test Report

A basic assessment that a weighing device was checked and meets require-ments, allowing multiple device tests on the same certificate with up to four test points per device.

Calibrate Local

Delivers a calibration certificate based on the Handbook 44, OIML or other local testing procedures and tolerances.

Calibrate ISO17025

Documents the results of the assessment of weighing performance using third-party accredited procedures. Suitable for automotive industry’s needs.

Calibrate SCC

The highest level of calibration procedure (metric only), for regulated applications, determining and documenting accuracy.

Find out when to calibrate your Scale:GWP® Verification

GWP® Verification provides the necessary in-

formation for lifetime calibration and testing. It

includes test methods, test intervals, test

weights, test tolerances and standard operat-

ing procedures (SOPs). With its risk-based

methodology, GWP® Verification saves testing

costs and boosts productivity by specifying

performance verification fine-tuned to your

business.

www.mt.com/gwp-verification-ma

piece counts are inaccurate. The interval can differ from daily calibration schedules to a calibration every couple of month or once a year. To be on the safe side, request an individual consultation by our Good Weighing Practice (GWP) team. This unique service provides you with all the information and guidance needed to sup-port your equipment’s accuracy over time.

www.mt.com/service-ma

Weight calibration set.


Visu

aliz

e W

eigh

ing

Dat

a Do You Really Know What’s Going On?Gain Insight Into your Production

Do you know how efficient your production operations really are? Now you can

find out by using your weighing data. Our new software, Collect+™, collects, vi-

sualizes and publishes your relevant data in real-time on a comprehensive

dashboard.

Check Operator EfficiencyOptimize Workflow

Speed up manualworkplace workflowIf weighing is performed manually in

your company, use Collect+ to check

worker efficiency. Check the through-

put for different product lines or verify if

products are within tolerance. Change

processes if inaccuracies occur and

check the results in real-time.

Make use of your production dataGet informed about your production

output. Let Collect+ software gather

data from your counting-scale sta-

tions. For example, don’t rely on in-

accurate molding-machine counters.

With this information, you can lower

the risk of restarting or retooling a ma-

chine.

Visualize production qualityVariations in your weighing results

can indicate quality problems. Use

checkweighers for quality or com-

pleteness checks and display the re-

sults in with Collect+. Reduce rejects,

material waste and process vari-

ances. Optimize and view improve-

ments right away.

View Production OutputGather Shop-floor Data

Collect Quality DataSupport Quality Initiatives

Collect• Receive weighing data from all mea-

suring devices on the shop floor, no matter the location

• Collect data from application as-sociated devices such as andon lights, bar code scanners, etc.

• Get data from third party devices

• Suitable for automated production

• Online results with 30-second refresh rate

Visualize• Production output

• Production output prediction

• Worker efficiency

• Quality data (input output of spec)

• Yield analysis• And more

Publish/Share• Results on a comprehensive

modern dashboard

• Share with colleagues

• View on mobile devices

Make use of Weighing Data with Collect+

Collect+ gives you a competitive advantage Machines on the shop floor constantly provide data, and you can use it to gain a competitive advantage. Collect+ is new data-collection software that captures production-weight and process data from every scale on your shop floor, including third-party weighing devices. Collect+ is updated every 30 seconds, giving you online insights into your production, no matter if automated or manual. Make use of weighing data for quality initiatives, process optimization and production control.

www.mt.com/collectplus-ma


Coun

ting

Solu

tions Semi-Automated Counting

Faster Counting, Fewer Costs

Easy-to-install semi-automated counting solutions offer high throughput and

labor-cost savings. In fact, counting scales could eliminate your need for a full-

time operator while speeding up your process.

www.mt.com/ind-semiautomated-counting-ma

Semi-Automated Control

Products can be transported via conveyor belt directly to the counting station or the scale is placed next to the extrusion or molding machine. Material flow can be controlled or redirected via the scale terminal. Semi-au-tomated solutions often provide the same benefits as completely automated ones, but at a lower cost and with much more flexibility.

Limited Operator Involvement

Use your resources wisely. Counting scales can save you ma-ny man-hours or even allow you to reallocate operator re-sources elsewhere in the factory. An alarm notifies the opera-tor when the package has reached the desired fill quantity. Boxes do not have to be transported to the counting station, saving time and reducing walking.

Shipping/Transport Boxes

Use shipping boxes of all kinds. The operator is notified if the filled boxes are replaced by a new empty one.

Weighing Platforms

Install one or more weighing platforms at the end of the process and place boxes or bins on top. Choose from a broad variety of platforms and terminals to tailor your installation to your specific capacity and process-toler-ance needs. For expert advice on selecting the right scale for your process, use our GWP® consultation service.

Terminal Counts, Redirects Material Flow and Creates Labels

The terminal includes a counting function to stop or redirect production when the preset filling target is reached. To control the material flow, connect a conveyor belt or pusher via the terminal’s digital I/O interface. Attach a printer to supply labels for the packages.

For more information

www.mt.com/ind-ma

Mettler-Toledo GmbHIndustrial DivisionCH-8606 Nänikon, Switzerland

Local contact: www.mt.com/contacts

MTSI 30302339

Piece Counting Excellence

You may be counting quickly, but are you counting correctly too? Accu-rately count metal, plastic and electronic components up to 30 percent faster with our counting scales. Our innovative colorWeight® display facili-tates fewer human errors and faster processes. With the ICS685 multifunctional scale, operators can count the smallest parts quickly, accurately and reliably.

Check out ICS685 counting scale www.mt.com/ICS685-ma

30% Faster, Always Correct Put Counting Scales to Work for You

Tackle the Seven Wastes of Lean Weighing Improves Production · Tackle the Seven Wastes of Lean...

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