1. Ingrid Halewijn, Gu van Rhijn For Improvement of Productivity, Flexibility and Ergonomics Bravilor Bonamat: Re-designing Production Processes in Manufacturing

2. TNO Quality of LifeRe-designing Production Processes in Manufacturing2 Trends in Manufacturing From market perspective Pressure on delivery time Increasing competitiveness (costs, quality) Increasing variety in product types Fluctuations in production batches Trends in operational management Throughput time versus real production time More focus on value added activities Reducing costs of work in progress Flexibility in process and organisation ‘Human factor is the most important resource’ (flexible, healthy, swiftly available) How can the design of production anticipate this?

3. TNO Quality of LifeRe-designing Production Processes in Manufacturing3 Bravilor Bonamat: Design of a Flexible Assembly Line Bravilor Bonamat Develops and produces coffee machines (for professional use): 280 employees 100,000 coffee machines in 6 product families per year Export to 80 countries Reason for the project Increase of production within the current available floor-space Increase of efficiency and flexibility Matching of 8 product types on one mix model assembly line

4. TNO Quality of LifeRe-designing Production Processes in Manufacturing4 Bravilor Bonamat: example of 4 varieties BoleroBolero XLBolero FBolero XL Turbo

5. TNO Quality of LifeRe-designing Production Processes in Manufacturing5 Bravilor: Step 1 Bottlenecks in Old Assembly Lines Use of space: 4 assembly lines for the various product types Logistic bottlenecks: supply to 4 lines High lifting of bins with heavy sheets Stretching to material behind the workplace Batch building: a lot of work in progress and long throughput times

6. TNO Quality of LifeRe-designing Production Processes in Manufacturing6 Bravilor: Step 2 Test Workplace Testing of the working height with various sizes of products and persons

7. TNO Quality of LifeRe-designing Production Processes in Manufacturing7 Bravilor: Step 3 Design of a New Assembly Line 1 Mix model for product family Pre-assembly directly opposite end-assembly Flexible switching between workplaces Height adjustability on the assembly line Racks are mobile, and can be turned over material for main line end-assembly pre-assembly workplaces

8. TNO Quality of LifeRe-designing Production Processes in Manufacturing8 Bravilor: Step 4 Design of Workplaces Pre-assembly supplies directly to end-assembly: tuning Adjustability of height: alternately sitting and standing posture Stock of small parts directly within reach Mobile racks for bigger parts

9. TNO Quality of LifeRe-designing Production Processes in Manufacturing9 Raising consciousness with personnel New workplace Measuring weight of bins Training people in a new way of working with K’nex Work sessions with personnel of assembly, logistics, planning, engineering

10. TNO Quality of LifeRe-designing Production Processes in Manufacturing10 Bravilor Bonamat: Results +15% Produce production -26% Floor space +300% Throughput orders -66% Tools and equipment Experiences More overview: at maximum height of racks Adjustability in height on the assembly line is being utilized Pre-assembly directly opposite end-assembly: is being experienced as pleasant, minimal handling and no storage in between People: ‘Materials directly at hand’

11. TNO Quality of LifeRe-designing Production Processes in Manufacturing11 Further questions? Please contact us: www.tno.nl Ingrid.Halewijn@tno.nlIngrid.Halewijn@tno.nl or Gu.vanRijn@tno.nlGu.vanRijn@tno.nl 0031 - 23 - 5549902