LEAN Solutions Delivering Results: A Success Story with Bauer Compressors
Bauer Compressors, headquartered in Norfolk, Virginia, is recognized as the world’s foremost innovative designer and manufacturer of state-of-the-art high-pressure compressor systems.
For over 75 years, the Bauer Group has led the charge in compression technology, earning industry-wide trust for its steadfast commitment to quality, safety, and durability. Specialized in markets such as high-pressure breathing air, defense/military breathing air, industrial air and gas, plastics technology, natural gas, and inert gas compression, Bauer Compressors continues to expand into new frontiers.
Today, Bauer pushes the boundaries of innovation by delivering total air solutions for industrial and breathing air applications. With a dedication to innovation and growth across diverse sectors, Bauer Compressors redefines industry standards and shapes the future of high-pressure solutions.
Recognizing the need for growth and limited room for it at their facility in Norfolk, Bauer Compressors proactively searched for ways to maximize their capacity within the walls of their facility. Cullen Moriarty, Senior Manufacturing Systems Engineer at Bauer Compressors, conducted a thorough evaluation of potential improvements within the facility.
Collaborating with our team at LEAN Manufacturing Products, we began a partnership focused on optimizing storage space and streamlining operational efficiency, encompassing both the fabrication shop and downstream processes at Bauer’s facility.
The LEAN WIP Advantage: Simplifying Processes, Boosting Efficiency
To begin the project, we analyzed their existing processes and operational flow. We identified that disorganized and crowded materials and assemblies within their fabrication department were impeding operator access, restricting workflow, hindering productivity, and reducing overall efficiency.
Parts flowed downstream with no clear pathway, creating bottlenecks that further delayed operations. A systemized process was of essence and the LEAN Work-in Process (WIP) Staging rack and tailored Industrial Pallet cart design were the pieces to the puzzle.
The LEAN WIP Rack facilitated a milk run process with their vendor.
LEAN WIP cartridges were integrated into the process, and the vendor loaded the full assemblies onto the WIP cartridges, delivering them directly to Bauer. With easy forklift access, loading and shipping of materials became streamlined and more efficient. Full assemblies were delivered to Bauer and the empty cartridges were shipped back to the vendor to be replenished. Upon reception of the cartridges from their vendor, Bauer maximized their vertical storage space and were able to load the cartridges directly into the WIP racking.
Each cartridge, shelf, and column labeled and organized provides an accurate and clear system of knowing exactly where materials are, at all times. From brake press to weld, cartridges began to flow through Bauer’s operations in a systemized process.
Downstream Efficiency: Industrial Pallet Carts Simplify Material Handling
Through collaborative analysis and discussion of Bauer's downstream processes, Lean's custom-designed and tailored Industrial Pallet Carts were seamlessly integrated to maintain the continuity of the LEAN process. This enabled parts to be efficiently kitted and follow their assemblies through to the final stages of production.
Additionally, to maintain a high level of organization throughout the process, perimeter features and color coordination on the carts were strategically designed to contain and manage the movement of parts, guiding them to subsequent operations in a controlled and efficient manner. The color-coded carts clearly differentiated the materials fresh from the vendor, initiating the first operation as blue carts, and assemblies prepared for the next stage in the production process as yellow carts.
The efficiencies between the LEAN WIP Racking and Pallet Carts led to great success, fostering significant improvements across Bauer's operations. The streamlined material flow with the Work-in-Process storage racking, facilitated by the Industrial Pallet Carts, resulted in a noticeable reduction in bottlenecks, leading to shorter cycle times and increased throughput.
The WIP material kitting on each cartridge, coupled with the carts' organizational features, minimized the risk of lost or misplaced components, ensuring that assemblies remained complete and on schedule. The improved organization of the workspace, driven by the carts and their distinctive features, significantly enhanced operator access and ergonomics. This contributed to a safer and more productive work environment, boosting employee morale and reducing the potential for errors.
The LEAN Result: Faster Production and Reduced Bottlenecks
Following a seamless LEAN implementation and the subsequent establishment of new processes and workflows, momentum began to build rapidly. Cullen Moriarty observed that the…
“LEAN products have really helped improve material movement and all-around safety within the fabrication shop. We no longer have forklifts traveling between the work areas and all around the shop, which reduces the chance of accidents or parts being damaged. With all the parts being up off the ground everything is more visible, and we aren’t ‘losing’ parts as often.”
Since integrating the LEAN WIP Storage racking and Industrial Rolling Pallet Carts into their operations, Bauer's lead times were significantly reduced, allowing the company to meet and exceed customer demands in a more timely and efficient manner. The integration of LEAN solutions led to a substantial decrease in lead time within their fabrication department, from approximately 11 days prior to implementation to just over 5 days afterward. This notable improvement would not have happened without the key collaboration and partnership between Bauer Compressors and LEAN Manufacturing. After checking in on how the process was evolving a few weeks after the LEAN integration, Cullen Moriarty shared,
"I had Purchasing, Planning, Inventory, Fabrication, and External Vendors all involved in this and we really needed everything to go right and it did. It has been a pleasure to work with the LEAN team and I’m sure we will be working with them in the future seeing how much their products have already benefitted Bauer. This is a major marvel for Bauer. Everyone is very pleased and excited to see the racks in action."
We look forward to continuing to build upon our partnership with Bauer Compressors, further streamlining the facility's operations and maximizing the long-term value of our collaborative approach. Fostering a culture of continuous improvement, our goal as LEAN is to help Bauer Compressors and other manufacturers around the country continue to thrive as leaders in their industry.
Watch the testimonial video below:
Product Information:
Learn more about the Work Cell Staging Rack Here
Read more details on the LEAN Industrial Rolling Pallet Cart Here
Still have questions? Give us a call at 262-875-3071 or send us an email at sales@leanmfgproducts.com
