ErmaLean

Presentation :

• ErmaLean is an evolutionary workshop that allows learners to be confronted with realistic industrial situations (assembly of a mechatronic unit) in order to conduct learning activities on the application of continuous improvement tools and methodologies as practiced in an industrial environment.
• Learning is done by alternating phases of production and periods of performance analysis which are sources of analysis with the Lean and Six Sigma tools, the application of developments can achieve the objectives expected by the customer in quality cost and time.
• The deployment of ErmaLean requires a minimum shop floor area of 100 m² for the different set-up configurations required for the activities.

Educational Activities :

• Different production sequences with evolving performances
• Progressive use of analysis tools leading to the evolution of workstations and procedures in order to finally reach the objective of customer order speed: the TAKT TIME
• Ranges of assemblies corresponding to different performance levels
• TP Lean and 6 Sigma with Excel file for each modifiable tool, provided with :
  • a tab for each document frame to be used in support of the exercise
  • an instructions tab explaining the chronology of the TP where the uses of the documents and materials are detailed
• The computer application allows the display (ranges, instructions...) and information feedback (time, measurement, defects...) of each station. These data are used for analysis and research of improvement solutions.
• Creation and improvement of routings in the Manufacturing Assistance software "Tulip"
• Implementation of the main Lean 6 Sigma tools (VSM, Kanban, Capability, Variability...). Conducting projects according to the DMAIC chronology: Implementation of process improvement project management tools and other teamwork tools.
• Lead time: Highlighting the impact of balancing items.
• Task Time: Measurement, analysis and evolution of the flows used: Material (batches, part to part) People (implementation) and information.
• Kaizen: Implementation of Kaizen tools (5S, TPM...)
• Quality: Implementation of Six Sigma tools (Capability; regression; R&R;...)
• Workshop management: Consideration of the different management parameters of a company.
• Ergonomics & Safety: Impacts of ergonomic and working conditions in safety standards

Highlights :

A management position with:

• PC of supervision in Wifi link
• Whiteboard and communication supports

Five modular assembly stations depending on the performance tested:

• elements of management and evolutionary steering,
• assembly stations allow several layouts (independent, in line, U-shaped)
• RFID traceability on assembly pallets and transfer between stations

Dynamic storage system sized for all the containers required for three product variants.

Assembly tools and control means integrated and partly connected to the supervision (measurement of screwing torques, dimensional, conformity test...).

The evolution towards the assembly of other products is possible by the simple adaptation of the pallets and the evolution of the various documentations.

Using Tulip :

• Elimination of all paper documents
• Easy and quick programming of the applications and very simple handling
• Possibility to make mathematical calculations for the determination of production indicators
• Visualization of all production-related information on a tablet or computer
• Customization of dashboards: by machine or by production line or by product
• Communication with remote machines through the Kepware communication server and the NODERED platform
• Possibility to use devices connected with the workstations (Scale, Caliper, Camera...)

Associated systems : 

ON00 : Cobot & Vision Station "Omron TM5" : Collaborative robot Omron TM5 4 kg R900 with embedded camera, on mobile chassis with height adjustment and work tray

ON17 : OnRobot's RG2 collaborative electric clamp option for OMRON Cobot Station

AG00 : AGV MIR100 Ermasmart

AG10 : AGV + Cobot "Mir100 + UR5 eSeries" Ermasmart

UR17 : OnRobot RG2 collaborative electric clamp option for Cobot UR

LN10 : Ermalean, Didactic assembly line for Lean 6 Sigma training

LN11 Option : Added value for a height adjustable workstation

EA02 Option : Industrial Vision Case Sensopart (For parts presence control)

LN13 Option : Torque control screwdriver connected to Tulip, with suction system for gripping and "head up" screw dispenser