Takt & Andon system

 

A takt system evens out the production flow and sets a standard cycle time. Bottlenecks are revealed and it has a positive impact on material management, manning, stocks and delivery time. Using the Binar LPS system, the customer has complete freedom to configure and change the takt system in order to handle a more flexible production system with an increased number of variants.

 

The system also features Andon, which is an approach to deal with disturbances in the process. During a disturbance, the operator can activate an alarm without leaving their workplace. The alarm is visualized with sound and light and stored along with the reason code. Improvement groups can then use the base to improve operations and thus increase productivity..

 

Unbalanced flow creates problems

 In a production flow where customer needs control the work rate, there are often major fluctuations in the production flow. An uneven flow can lead to a whole series of problems. Material supply finds it difficult to keep pace with the fluctuations and operators are exposed to unnecessary stress, subjecting them to a hectic, disjointed working environment.

 

The uneven material flow frequently results in a shortage of materials, which means that buffer stocks and costly storage need to be created. Substantial fluctuations in volume also affect the company's suppliers, which then leads to delivery delays, material shortages and a possible deterioration in quality.

 

Red curve = Customer-controlled, unbalanced flow. Green curve = Balanced flow

 

How to balance a flow

The assembly of a product is divided into roughly equal parts, a process known as balancing the production rate. A standardised working approach is then introduced, timed and documented step by step. Divide sub-assembly across stations placed in a flow, preferably without parallel branches. Difficult, time-consuming assembly and infrequent assembly are placed outside the flow and are termed pre-assembly.

 

A support system is then required to visualise the production rate – a takt system. Work at stations that are at a standstill in conjunction with transfer, where the rate has been reduced to 0, is known as Stop & Go. A more efficient way of avoiding loss of time in conjunction with transfer between stations is to have a continuously driven flow, which is often used in the automotive industry.


There are many positive effects. A less stressful working environment, reduced buffer stocks, reduced waste, improved quality and increased productivity. A takt system shows clearly where there are disruptions and bottlenecks in production and creates a basis for an ongoing improvement process.

 

Advantages of a takt system

  • Variable customer demand is spread out to achieve an even production rate.

  • Delivery times can be shortened and stock requirements reduced.

  • Continuous processing of the product cuts the waiting time for operators and machines, resulting in reduced production time.

  • Creates stability in the process and conditions for adopting a standardised work routine.

  • Material flows are evened out, reducing the risk of material shortages.
  • Highlights potential problems and creates a base that can be used by groups to improve process efficiency.

  • Staff planning is simplified.

  • Contributes to improved quality at all stages in production.

 

 

 

System design

The system is built up using Binar's standard components for production support systems. The control and monitoring software is installed on the server and controlled from client computers. A link from the network (Ethernet) passes via Gateway LP201, which also provides the power supply for the system. Communication then takes place on a Can bus, which means highly flexible installation. All connections are M12 connections and all cables are prefabricated in different lengths. This makes installation extremely simple and it is just as simple to change the system configuration if necessary. Signal exchange with the process takes place via an LP315 I/O box, where it is easy to connect lights, sensors, buttons etc. To provide 'ready' signals from an operator and light indications to an operator, button devices LP373, LP376 and LP220 are used.


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