Racking reduces lineside stock levels

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Robert Bosch has chosen the LeanTek modular system in a project to dramatically reduce stock levels within the final assembly area at its Cardiff plant. The introduction of bespoke LeanTek live storage racks has resulted in a 58% reduction of lineside containers.

The company is keen to maintain its reputation as a dynamic, performance-orientated organisation. The Bosch Production System (BPS) was developed as part of a worldwide initiative to improve production systems and related processes. Both strategic and operational changes are undertaken to ensure that there is a long-term culture of continuous improvement.

The BPS team in Cardiff knew that stock levels both line side and within the stores had to be drastically reduced in order to maintain the lean manufacturing principles. The Tube & Bracket Company, UK distributor of the LeanTek product, was invited to view and assess the final assembly area. It presented a comprehensive and cost-effective solution, designing a variety of bespoke live storage racks to integrate with the existing permanent fixtures.

All racks were fitted with reinforced roller track to promote first-in-first-out stock rotation, and allow part delivery to the exact point of use, rather than the end of the line.

Mark Ryan, of Robert Bosch, says: “The LeanTek modular system’s flexibility is of fundamental benefit to the ever-changing requirements within our production area. In addition to live storage racks we also have the option of building adjustable workstations and tables from the same system, which will maintain uniformity.”

The racks were assembled at the Tube & Bracket Company’s factory in Banbury and positioned on site at Robert Bosch within five days of order placement. The modular nature of the system means that if any racks require modification in the future, components are available on a next-day basis.

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