How we designed and implemented a production line (One Piece Flow) in collaboration with Lean Industry
Production optimization today is not just about changing the layout. It means connecting process analysis, equipment design, logistics, and operator work into one functional and stable system.
In this project, we partnered with Lean Industry s.r.o., a company specializing in the implementation of lean manufacturing principles in industrial companies across the Czech Republic and abroad. Their expertise in process analysis and production flow design was complemented by our modular construction solutions from ENPRAG.
Initial situation
The original production setup resulted in unnecessary movement, inefficient material handling, and limited flexibility when changes were required. The goal of the project was to create an efficient production line based on the One Piece Flow principle, which would accelerate material flow, improve workplace ergonomics, and reduce operational losses.
How the new production line solution was created
ENPRAG modular structures formed the foundation of the new production line and enabled flexible adjustments during implementation.
This made it possible to respond to real operating conditions and continuously optimize both the line layout and individual workstations:
- quick reconfiguration of workstations
- ergonomic adaptation for operators
- easy integration of logistics elements
- stable and precise mounting of technological equipment
- future scalability without major structural modifications
Implementation directly in production
The production line was assembled directly at the customer's site, with a focus on gradual implementation of individual parts.
This approach made it possible to:
- immediately verify production times
- test workplace ergonomics
- fine-tune the placement of components and tools
- eliminate unnecessary movements before final launch
ENPRAG modular structures enabled quick adjustments without the need for complex interventions or production downtime, significantly reducing ramp-up time.
The line was fine-tuned directly in operation, allowing hidden inefficiencies to be identified and eliminated before launch.
Collaboration that makes sense
Lean Industry s.r.o. led the entire project from initial analysis to final implementation. Their experts defined the requirements for the new line, designed the optimal production layout, and coordinated the execution.
ENPRAG delivered a construction solution that precisely met these requirements and enabled fast and efficient implementation in practice.
The end customer received a complete solution:
- process analysis and solution design by Lean Industry
- construction implementation by ENPRAG
- fast production launch with minimal adjustments required
The workstation layout minimizes material handling and supports a smooth production flow.
Project results
The implementation of the new production line delivered measurable improvements:
- –28% production area
- –100% intermediate pallets
- –1.5 operators per shift
- +13% performance per operator
- –66% production lead time
The result is faster, clearer, and more flexible production with lower space and labor requirements.
Customer reference
Ing. et Ing. Jakub Myška, CEO of Lean Industry:
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„Working with ENPRAG always makes sense. I appreciate their speed, flexibility, and above all, their seamless communication. Thanks to this, our customers receive solutions in the shortest possible time and at top quality. These values are also the foundation of Lean Industry s.r.o. – fairness, open communication, and a focus on truly functional solutions that deliver long-term value.“ |