Since 2022, we have been collaborating with Enprag on the development of new Bento Boxes (BB), which are used to transport materials in the JIS mode from the picking zone of the supermarket to the assembly workstations. The goal was to optimize the transportation of materials between different production zones, reducing the time required to search for and transfer components, while also minimizing the risk of component damage during transport on the MEX and LDR lines.

Reasons for Replacing the Existing Bento Boxes

Before the introduction of the new carts, the existing ones were incompatible with modern smart milk-run systems and exhibited several significant drawbacks. The main problems included:

1. Disorganization: The old Bento Boxes led to longer times required for selecting components, resulting in frequent complaints about damaged parts. Especially painted parts were often stacked on top of each other, leading to damage, as well as heavy parts placed on fragile components, which caused additional damage.
2. Poor space utilization: The old carts had unused space, but due to inappropriate dimensions, it could not be fully utilized. Placing parts on top was impractical, leading to inefficient organization.
3. Inadequate transport method: The system of rods without safety pins posed a safety risk, as the rods tended to detach from the pins, potentially leading to the Bento Box disconnecting from the convoy. Handling was complex, and operators had to bend over when connecting and disconnecting the carts.
4. Ergonomics: During assembly, the placement of parts was not tailored to the operator's needs, leading to unnecessary delays and increased error rates.

Purpose of the Investment

The aim of the project was to design, prototype, and mass-produce a new type of Bento Box for the LDR assembly line, which would replace the ten-year-old carts made from welded steel.
The new carts use the ENPRAG modular tube system with a standard base and a custom frame designed for the safe and efficient storage of components. This system ensures a lower risk of component damage and simplifies the operators' task of selecting the required components on the assembly line.

 

Bento Box Designs

 

Improvements and Benefits of the New Generation of Bento Boxes

Thanks to the collaboration with Enprag, new Bento Boxes (BB) have been developed that eliminate many of the issues associated with the old ones:

1. Modular System: The new carts are made from a tubular system, which allows flexibility and easy design modifications. The frame of the cart is composed of metal connectors and tubes that can be reconfigured using an Allen key, making it easier to adapt to changes in the production program.
2. Improved Space Utilization: The new carts have an optimized design that allows for better space utilization. Parts are custom-arranged, ensuring efficient component organization and reducing unnecessary movement during transport.
3. Compatibility with Modern Systems: The standard base of the Bento Box is compatible with the smart milk-run system and upcoming AGVs (Automated Guided Vehicles), meaning the carts can be easily integrated into modern automated production. This compatibility brings further efficiency to the transportation processes and ensures smooth production flow.
4. Improved Ergonomics and Safety: The new Bento Box design allows for easier handling, eliminates the need for operators to bend over when connecting and disconnecting the carts, and minimizes the risks associated with mechanical malfunctions. Additionally, the ergonomic placement of components reduces the risk of errors and increases the speed of work on the assembly lines.

 

     

 

Results and Savings

The new Bento Boxes delivered positive results within the first few months. The main benefits include:

1. Labor Capacity Savings: Due to better organization and improved ergonomics, the labor effort in the supermarket and on the MEX/LDR assembly lines has been reduced.
2. Reduction in Component Damage: With the new system, there has been a significant reduction in the number of damaged components, leading to lower costs for repairs and replacements.
3. Increased Efficiency: Thanks to better work organization and compatibility with smart systems, the transportation of components has accelerated, and the time required to select components on the assembly line has decreased. Operators now have quicker and more efficient access to parts, contributing to increased productivity.

Expected Return on Investment (ROI) is 2.4 years, which highlights the effectiveness of the new solution. The optimized solution not only improved the organization and safety of transportation but also opened the door for additional design adjustments when changes occur in the production processes.
Enprag has proven to be a flexible partner, capable of quickly responding to conceptual changes and making operational adjustments directly on the prototypes intended for testing. As a result, it was possible to deploy, on average, one new set of carts per month, completing the replacement of the entire fleet within two years.

 

                                                                                                                             Doosan Bobcat EMEA s.r.o.