Lean Manufacturing. Avoid Wastage with Smart Weighing Solutions

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1 Lean Manufacturing Avoid Wastage with Smart Weighing Solutions

2 Lean Manufacturing Weighing Can Make You Lean! Smart Weighing Solutions for Lean Production Lean manufacturing and lean management are of utmost importance, as they can help to minimize costs and maximize efficiency. Benefit from our diverse range of weighing solutions and continuously improve your production processes. Wastage should be avoided at all costs, and this is lean manufacturing's main objective. The advantages of this production practice include high-quality products, punctual deliveries, a significant reduction in stock inventories, as well as relieving employees and reducing machining times and space requirements. So that's the theory. METTLER TOLEDO offers practical solutions that will allow you to optimize your production processes. Avoid wastage Precise, reliable and fast weighing is the key to avoiding wastage and keeping costs to a minimum. Avoid overfilling with accurate counting systems. Order pick parts from an individual piece weight of g and select matching bulk weight scales up to a maximum capacity of 12 tons. Our counting specialists will be happy to show you how to avoid costly under and overfilling. Speed up manual processes... with the colorweight colored weight display. Increase the efficiency of your production staff with the colored tolerance display that quickly and clearly states whether or not the weight or quantity is within the permitted tolerance. In addition to this, colorweight can also help to minimize errors. Thanks to its robust design with IP69k protection, the weighing terminal itself can withstand environments prone to dust, oil, moisture and severe vibrations and guarantees long operating periods without incurring problems. Use our online value calculator to discover how much time and money you could save with colorweight. Avoid errors with user-prompted formulation systems. The generation of formulations and mixtures is prone to errors, which can have a costly im- pact on subsequent production steps. Our weighing systems guide the operator through the formulation process and can help to minimize mixing errors. All process steps are simultaneously documented on the PC and/or in paper form and are therefore easily traceable. Optimize quality with integrated Statistical Quality Control (SQC). Monitoring the piece weight, dimensional accuracy, surface structure, appearance, volumes and other parameters is child s play with our modular PC-based quality control system. Thanks to integrated measuring stations such as scales or digital vernier calipers, data can be recorded online and then analyzed by the quality software. Should any deviations occur, production can be interrupted immediately. Increase the availability of the scales thanks to their robust design and optimum service. Floor! Best practice examples! Reduced overfilling, prevention of wrong deliveries, faster Efficient and manual operations page 4 5 error free storage page 6 7!picking 2 METTLER TOLEDO Lean Manufacturing Significant time savings due to shorter order routes page 8 9

3 scales in particular are often exposed to harsh working conditions. It is for this reason that METTLER TOLEDO floor scales come equipped with special adjustable rocker feet, which ensure optimum force transmission to the load cell at all times and thereby prevent any damage to the load cell due to lateral shearing forces. Furthermore, up to 15 tons can be transferred over heavy-duty scales, meaning that the scales themselves can be easily used by heavy-duty fork-lift trucks. The expert METTLER TOLEDO calibration and maintenance service also contributes to the high availability of the scales. Reduce employees workload with our modular weighing systems. With or without the colorweight display, METTLER TOLEDO offers the world's most extensive range of weighing terminals and platforms with the most diverse designs, sizes (including free size for floor scales) and accessories. Our specialists are always on-hand to provide you with professional support, meaning you can provide your employees with an ergonomic workplace and thus reap the benefits of efficient operational procedures. Continuously improve your processes... with flexible weighing solutions. METTLER TOLEDO scales can be adapted to changing ambient conditions at any time thanks to their mobility, Plug n weigh functionality, modularity and versatile accessories. The pallet scales and elevated floor scales, which are not secured to the floor, can be used at any location for a wide range of purposes, and thanks to the Plug n Weigh functionality can be separated as often as required from the weighing terminal and then reconnected without the weighing data and calibration values being lost. This allows the scales to be moved and the cable length to be extended by up to 100 metres at any time without the need for additional calibration work. Versatility lies in METTLER TOLEDOs product range. Round off your weighing station with barcode readers, label printers, roller conveyors and stands available in various sizes, or develop your weighing stations into a networked quality control system that can be fully integrated into your production systems. What matters to us is that you are able to continuously improve your processes so that your products can be supplied on time, in the required quantity and to the highest quality, while keeping costs to a minimum. For more information contact us! Optimized transportation in shipping areas page Improved quality and increased savings page 12 13!and Reduced material wastage errors page METTLER TOLEDO Lean Manufacturing 3

4 Reduced Overfilling Innovative Process Optimizations Realized with Checkweighers and Counting Scales To the benefit of its customers, the Austrian metal fittings company, Blum, places great importance on the continuous improvement of processes. Innovative checkweighers and counting scales from METTLER TOLEDO are a key factor in increasing operational efficiency, preventing inaccurate deliveries and eliminating costs incurred from overfilling. Over fifty years in the business With over fifty years of continual success, the Vorarlberg-based company is today a global player in the manufacturing of primarily kitchen-based hinge, lift and pullout systems. Blum focuses on products and services that simplify day-to-day tasks for its customers. Accurate deliveries When it comes to the manual order picking of metal fittings, METTLER TOLEDO scales ensure that customers are supplied with exactly the products they ordered, thus significantly reducing the margin of error. And this is how it works: The first scale checks whether the correct quantity of metal fittings has been picked. This is immediately visible to the operator by the color of the display. The IND449check+ scale terminal display has color backlighting. If products are under or overfilled, the display lights up red. Once the target weight is reached, the backlighting color changes to gray. In the next operating step, the picked product is sealed and then packaged into shipping cartons. Here, it is the turn of the second scale to ensure that the correct quantity of packages is shipped per carton, by counting the packages. As soon as the correct quantity of packages is contained within the carton, the backlighting of the IND449check+ terminal display changes to green. A worthwhile investment in process optimization For Blum, METTLER TOLEDO checkweighers and counting scales with color-backlit displays have proven to be a worthwhile investment in three different areas. Quality control manager, Mr. Johann Schmidinger, explains: "Firstly, costs incurred from overfilling can be significantly reduced; secondly, incorrect deliveries can be prevented and thirdly, the operational efficiency of users can be maximized." The scales can be operated intuitively and thus greatly reduce the amount of work involved, as operators no longer need to stare at illegible digits, but can instead immediately identify Yellow weight below tolerance Green the box is full! Red weight above tolerance Completeness checks with colorweight pay for themselves! 4 METTLER TOLEDO Lean Manufacturing

5 Reduced overfilling, prevention of wrong deliveries, faster manual operations whether the target value has been reached, even out of the corner of their eye. This increases the efficiency of costly manual labor. Thanks to the high-precision K series weighing platforms from METTLER TOLEDO, Blum can rest assured that it has the required accuracy to ensure that only the correct quantities are packaged and shipped. With IP67 protection, the weighing platform is also fully dust-proof and ideally suited for use in harsh environments. Continually improving processes Blum places great importance on continually improving its processes. METTLER TOLEDO solutions help across the board, from incoming goods, to production and storage, right up to outgoing goods. On automated packaging lines, dynamic checkweighers from METTLER TOLEDO Garvens reliably check the package is complete and sort and reject those that are incomplete. During production, counting scales ensure that even the smallest of components, such as o-rings, are counted reliably, accurately and efficiently. In this case, Blum relies on a two-scale system incorporating a high-precision analytical scale for reference purposes and a BBK462 volume-measuring scale. This guarantees accurate quantities, even in the case of extremely small parts. The large, brightly backlit display of the BBK462 intuitively guides the operator through the counting application. Both the detection of new piece weights and the actual counting procedure can be operated simply and effectively. Not even high-bay warehouses prove a problem to the METTLER TOLEDO scales in ensuring the correct weight. Each pallet to be warehoused is weighed on the roller conveyor scale and the PTHN process weighing terminal transfers the weighing result directly to the warehouse control system. This integration automatically ensures that no overloaded pallets are warehoused. Service makes it all possible Employees of Waagen Scheffknecht GmbH, METTLER TOLEDO s sales partner, guarantee that Blum is provided with professional support and the appropriate services relating to the scales. Mr. Schmidinger explains: "We re benefiting from comprehensive support, which is tailored to our requirements, as well as from expert installation, calibration and verification services. Thanks to the convenient location of Waagen Scheffknecht, we don t need to worry about the speed of the service the company provides, for example, if our scales need configuring or maintenance work or if further training is required." Efficient weight inspection prior to storage 100% completeness check with METTLER TOLEDO Garvens checkweighers METTLER TOLEDO Lean Manufacturing 5

6 Efficient Storage Punctual Deliveries that You Can Rely on Thanks to the Integrated Counting Solution The Swiss company Gewitec the clamping and slotted nut specialist relies on the efficient and flawless storage of its products. This is where METTLER TOLEDO weighing systems lend a hand and support Gewitec in delivering its products punctually and reliably; giving this innovative company a real competitive edge. IND465 weighing terminal with a robust PBA330-B60 weighing platform, barcode scanner and label printer. Delivering our customers orders on time is what makes our production profitable. For products to be delivered across the globe, there is a need for creative logistics and shipment solutions. To achieve this objective, Gewitec relies on an innovative partner that has years of experience under its belt. The experienced counting specialists at METTLER TOLEDO were able to meet Gewitec s requirements in full. Gewitec s requirements Mr. Beat Rüfli, logistics manager at Gewitec, describes his requirements as follows: "In terms of the counting solution, we required a reliable, user-friendly and efficient approach. We have been provided with a comprehensive, intuitive and easy to operate weighing solution that is fully networked with Sage, our ERP software system." Efficient and error-free storage The manufactured parts are stored in standardized containers and their tare weight is then adjusted within a narrow tolerance (+/-5 g). Mr. Rüfli explains, "We rely on the weight of the containers being constant where possible, so that the piece number can be determined reliably and accurately. Otherwise, the seeds for counting errors will have already been sown." The counting procedure itself is extremely simple: Staff members place baskets onto the scale and select the product on the production order using the barcode scanner. The scale automatically calls up the saved parameters, such as the tare weight and the reference weight, and calculates the piece number. All this takes just a split second. The system then prints off two labels with the date, time, product number, piece number and product name. The label serves both as documentation for the storage order and as the container label. Intuitive and easy to operate Thanks to the barcode scanner, all that needs to be operated at the IND465 weighing terminal is the label printer. The rest of the system is set automatically. Mr. Rüfli: "We couldn t wish for a more efficient procedure. The work required by our staff members is kept to a minimum with the self-explanatory weighing process and, what s more, they are always able to rely on accurate piece numbers for stored products." SmartManager: intuitive and easy to operate application and configuration software 6 METTLER TOLEDO Lean Manufacturing

7 Efficient and!error free storage Fully integrated An additional requirement was to integrate the counting solution into the existing ERP system, so that master data for products could continue to be managed centrally. With the SmartManager application and configuration software from METTLER TOLEDO, product and scale data can be conveniently monitored on the PC. The software not only enables the scale to be easily configured, but also establishes a network with existing product management systems. "By connecting the SmartManager to our ERP system, we are saving the expense of a dual product management system, assuring the quality of our master data and at the same time benefitting from an end-to-end and easy to use counting solution," explains Mr. Rüfli, who then goes on to say, "The professional support provided by METTLER TOLEDO s counting specialists has impressed us across the board and means that we now have a solution that is better than we could have ever imagined." In an addition to this, Gewitec is now testing the integration of the counting system into the warehouse management system. A final word from Mr. Rüfli: "At Gewitec, our aim is to continuously improve our processes. Thanks to the counting solution we have now, we will also be able fufil this objective. The weighing system can be used flexibly in terms of its location, be supplemented by a wide range of accessories such as roller conveyors or additional weighing stations and can thus be adapted to changing ambient conditions in no time at all. Day in day out, our customers in the automobile and aviation industry, in mould making and tool manufacturing, and in the wood industry are benefitting from this flexibility, as they are always able to count on reliable and punctual deliveries." For more information: An integrated counting solution ensures efficient and flawless product storage METTLER TOLEDO Lean Manufacturing 7

8 Significant Time Savings Efficient Order Picking Thanks to Mobile Database of Articles Significant time savings were made due to short order picking routes with a mobile solution. With an optional, simple control method, errors occurring as a result of confusion between different parts are prevented. Hermle Mechanische Uhrwerke & Drehteile GmbH, based in Reichenbach, Germany, specializes in precision turned parts. They also manufacture mechanical clockworks. Clockwork manufacturing orders are made out at the storage location. This means that traveling distances can be shortened if a variety of different parts need to be picked. The article IDs and piece weights of the parts are saved in the mobile IND690 weighing terminal. With the SysDataManager program, article data is edited on the computer efficiently and conveniently and data loss is prevented. An article can be called up using a keyboard or barcode reader, automatically making the correct individual piece weight available for counting. Thanks to this method, determining the individual weight based on a reference quantity, which tends to be time-consuming and faultprone, is eliminated. A plausibility check may be carried out to check whether the actual piece weight corresponds to the saved value. During this check, the selection of a wrong article number or a wrong part from a shelf will be detected. For the purposes of identifying the picked parts, a label is immediately printed with the article ID, quantity and individual weight. METTLER TOLEDO has met customer requirements with a freelyprogrammable IND690 and a PBA330-B60 scale. The rechargeable battery means a guaranteed mains-independent power supply. The whole system is installed on one carriage. 8 METTLER TOLEDO Lean Manufacturing

9 Significant time savings due to shorter!order picking routes Customer benefits Mobility thanks to mainsindependent power supply Short routes during order picking No time is lost or counting errors are made when determining the piece weight Simple data management and backup using the computer Optional correct part check Thanks to the mobile solution from METTLER TOLEDO, Hermle GmbH has significantly increased the efficiency of its order picking procedures. How long are your walking excursions? Contact us for an analysis SysDataManager The SysDataManager is PC software used to manage articles, tables and configuration data of the IND690 weighing terminals quickly and simply. METTLER TOLEDO Lean Manufacturing 9

10 Optimized Transportation Do You Want to Save Time and Processes in Logistics? Not a Problem for Heavy-duty Scales. Böllhoff, a leading provider of connection, installation and systems engineering puts its trust in robust heavy-duty scales from METTLER TOLEDO for incoming goods. The fact that up to 15 tons can be transferred across the floor scales means that they can be driven over by fork-lifts and time and travel processes can thus be saved. Diversity is key at the German family-owned company, Böllhoff. Whether you require screws, joints or rivets Böllhoff offers tailored solutions at the highest level of quality even for particularly demanding tasks. Continuous improvement With certification in accordance with ISO/TS 16949:2002, Böllhoff is aiming to become a zero-defect organization by means of continuous improvement. Simplifying processes to increase efficiency and to ultimately improve the quality for the customer plays a central role in Böllhoff's day-to-day business. Day in, day out, large quantities of materials are delivered at goods receipt. This is where the most resistant floor scale from METTLER TOLEDO the DSF line is called upon to check deliveries for completeness. Mr. Hayrettin Sariz, logistics manager, opted for the DSF3000 heavy-duty scale so that pallets can be checked in a non-time-consuming and spacesaving manner: "Thanks to the high-quality and robust design, our fork-lifts can drive over the scale without incurring any problems. This increases efficiency levels in the goods receipt area, as no time is wasted on maneuvering around the scale and space can also be saved". No problem for fork-lifts The DSF heavy-duty scales withstand collisions with the heaviest of devices, can handle weights of up to 15 tons being transferred across them and are thus ideally suited to harsh conditions in the field of logistics. The floor scale has not only allowed the flow of goods to be processed more efficiently, but also minimizes the risk of injury to employees. It has also been possible to eliminate the need for protective equipment such as safety barriers and thereby reduce the risk of tripping. Mr. Sariz confirms: "The heavy-duty scale meets our requirements in terms of its stable design and the process optimizations achieved through this. It requires less work by our employees, while driving down our costs. METTLER TOLEDO's installation, maintenance and calibration services maximize the availability of the scale and have been awarded DKD certification in accordance with ISO/TS 16949". For more information: 10 METTLER TOLEDO Lean Manufacturing

11 Optimized transportation!in shipping areas Solid and Accurate Floor Scales Made for Shipping Departments A wire manufacturer relies on Rocker Foot suspension for floor scales in his busy shipping department where there is a high volume of fork lift traffic. KOS WIRE EUROPE s.r.o., a member of the South Korean KOS GROUP, built a new plant for the production of stainless-steel wire in Lovosice in the Czech Republic. The company has invested EUR 21.5 million and employs 90 people at its three sites. KOS produces several types of stainless steel wire, which is particularly suitable for use in the automobile industry. KOS needed 4 floor scales to weigh the wire reels. The tare weight of the empty reels had to be set numerically. Each scale had to be linked to the IT System with an automatic interface. The scales are to be used in the busy shipping department, where there is a large number of fork lift trucks and pallet jacks. In such a busy environment there is an increased risk of fork lift trucks or pallet jacks sliding the pallets onto the scale while they are still moving. The sliding applies sheer forces which can destroy the load cell if it does not have sufficient protection. PFA574 and PUA579 floor scales from METTLER TOLEDO are equipped with the Rocker Foot to protect the load cell from sheer forces. The METTLER TOLEDO service team installed two PFA574-E3000 floor scales with a capacity of 3000kg for the heavy reels which are transported by fork lift trucks. For the less heavy reels, which are transported with pallet jacks, they installed two PUA574s with an ultra low profile. The ultra low profile allows the pallet jacks easy access to the scale. For more information: The Rocker Foot ensures optimum force transmission into the load cell at all times. It allows the weighing platform to be moved laterally to its safety end stops. This prevents any damage to the load cell due to lateral shearing forces which might occur when loads are forcefully loaded onto the scale. Not all commercially available scales are protected from these shearing forces. KOS uses the solid IND445 Industrial Weighing Terminal, with a memory capacity for up to 99 tare weights. It has an optional Ethernet TCP/IP interface to communicate with the IT System. The PFA574 floor scale with a capacity of 3000 kg is used to weigh wire reels up to 2000kg. The loading is performed by fork lift trucks. The PUA579 ultra low profile floor scales for 1500kg. The low profile allows easy access for pallet jacks. The solid construction can withstand the load from the wheels of pallet jacks. METTLER TOLEDO Lean Manufacturing 11

12 Improved Quality Quality Assurance Increases Savings The plastic cups that we get at drinks machines in the workplace, on the train, on the airplane or at the kiosk are essentially mass products. Nevertheless when they are being manufactured they have to meet up to strict twelve quality standards. At the factory of the well-known manufacturer Bellaplast AG in Altstätten (Switzerland) the measuring parameters are intentionally set to a challenging level. The checks are carried out by a Statistical Quality Control system from METTLER TOLEDO. "We want to ensure that the cup flows effortlessly through the machine. It must feel good when drinking and comfortable in the hands of the consumer. There should never be sharp edges or an unappetising odour, and optically the visual impression should also be good", says Harald Metzler, Quality Tester at Bellaplast. Such ambitious objectives can only be attained by means of a multi-layered checking system. The company has set up checking stations on four work benches in the production plant which are equipped with precision balances controlled by METTLER TOLEDO FreeWeigh.Net software as well as other measuring devices. Up to twelve different quality criteria are investigated on samples and the values are stored with unprecedented efficiency. Odor With regard to weight, the graphic display of the form tool shows which stamp is producing precise cups (green), ones that are too heavy (red) or that are too light (yellow). The injection molding machine can now be specifically adjusted. up to twelve different quality criteria are tested Optimized quality with integrated Statistical Quality Control (SQC) 12 METTLER TOLEDO Lean Manufacturing Systematic sample checks "This software solution gives us a tangible and significant benefit", IT Manager Manfred Oertle told us when we visited him on site. "Each machine operator regularly takes samples from his current production which incidentally operates uninterrupted from Monday to Color Lip roll thickness

13 Improved quality!and increased savings Quality monitoring screens Weight Courtesy Bellaplast Courtesy Bellaplast Wall thickness Saturday mid-day. Immediately after entering the article number on his PC, a corresponding window appears on screen showing the test plan relating to this article. He can then spend around 10 to 15 minutes working through the individual test criteria: weight, wall thickness, lip roll thickness, color, odor etc. All measurements and readings are then transferred into the same, electronically stored test record; we no longer use tick lists." New: Graphic image of the deep draw batch on screen Machine operator Alexander Ulm arrives at the control station with the latest sample series (54 cups). He lays cup after cup on the electronic precision balance which has a display accurate to one hundredth of a gram. He then measures the wall thickness with a micrometer which transfers his data via cable directly to FreeWeigh.Net. Other criteria are entered numerically. The new feature that Alexander Ulm notices is the graphic image of the injection moulding batch on screen in front of him. Green indicator: cup weight correct; yellow indicator: too light; red indicator: too heavy (for each indicator the measured weight of the cup is also displayed, e.g g). The machine operator can therefore see not only whether there are deviations in this batch but also exactly where they have been caused by the form tool. Thanks to this graphic screen image it has now become possible to make specific adjustments on the injection molding machine. Even the tiniest quantities can be a decisive factor "The machines have a high hourly delivery rate of approx pieces per hour. This fine adjustment produces real savings in materials for us", says Manfred Oertle. "If there are considerable weight deviations we do not only take action to prevent later malfunctions in drinks machines but also act to prevent materials wastage. Even a tenth of a gram overweight per cup would rapidly add up to high additional materials costs of 10 kg/hour." Just the 54 cups included in this sample generate over 500 items of data. Manfred Oertle: "With such an abundance of data it is important to store all the information in our central database under a pre-defined term. If complaints arise we respond even quicker because we have achieved the level of trace-ability which we in fact always wanted to have for our production process. Furthermore we are certain that all checks are actually carried out." For more information: Best practice Overfilling costs Even as small overfill can have a huge impact to your company's profit. Process Improvement METTLER TOLEDO System Solutions help you optimize your production process without jeopardizing regulatory compliance! Test it now with your own product Statistical Quality Control Return on Investment Even a small overfill can have a huge impact to your company's profit. Reduce overfill of your products and improve consistency and production yield! Test it now with your own product! Reset Form Print Form Currency Package sales price Weight unit Cost of raw materials per Parameter Nominal fill quantity Number of packages produced per day Number of production days per year Production mean value Overfill per package Overfill per day Overfill per year Overfill cost (=loss) per year or Packages not produced Missed revenue from unsold packages Visit us now at and let us help you optimize your production process! Mettler-Toledo AG, Switzerland, MT-BASY METTLER TOLEDO Lean Manufacturing 13

14 Reduzed Material Wastage Batching of Composite Sinter Material Traceable according to TS16949 The FormWeigh.Net batching software makes management of recipes, raw material and dosing of different components more efficient and more accurate. It guides operators, with instructions, through the process and helps to reduce mixing errors. All process steps are documented in the IT system and on a print-out for uninterrupted tracking and tracing. A composite sinter metal manufacturer in Germany manufactures bearings with layers of self-lubricating material that require either no lubrication or lubrication only during the initial installation, and no further lubrication for more than 30 years. These bearings are used for shock absorbers, hinges, gears, pumps, valves, car seats, vibration dampers and other equipment requiring bearing materials. The customer s commitment to the environment extends not only to lead-free dry bearing material, but also to solvent-free manufacturing processes. The innovative technologies are applied in sophisticated, state-of-the-art manufacturing and development facilities. Customer Requirements The customer was looking for a solution to make the batching process for composite sinter material more efficient. The creation of batch protocols for traceability to comply with ISO/TS16949 had to be automated. The entire recipe management process should be performed on a computer. Operators needed to be guided through the batching process with instructions on the screen of the weighing terminal in order to avoid bad batches. Each step of the process had to be confirmed after completion. The protocol of each batch had to include raw material identification, net weight of all components, date, time and identification of operator and all operator confirmations. A particular requirement was the extraction of a part of a liquid component at the end of the mixing procedure. This extraction also had to be fully documented. Finally, the system had to be open for future connectivity to the already existing SAP system. Solution: METTLER TOLEDO in Germany fulfilled the customer s need for recipe management, raw material management, user guidance, tracking and tracing with the FormWeigh.Net software. This batching software runs on the MS Windows XP operating system. Data is stored and managed on the MS SQL Server 2005 database system. The FormWeigh.Net software is installed on an ID30 weighing PC, designed for industrial use. The stainless steel housing meets the IP69k protection standard. This protection standard is needed, since powders and liquid components that can produce dust are mixed directly next to the ID30. The batch is weighed on a KCC150 scale made of stainless steel. It has a full capacity of 150kg with a readability of 1g. The versatile scale meets the IP67 protection standard. Conclusion: The customer is confident that the company can reduce the amount of waste raw material and increase batch quality. The documentation for tracking and tracing is available, as all relevant data is stored in the SQL database. During batching, the operators are guided through the process by the clearly visible instructions on the weighing terminal. For more information: 14 METTLER TOLEDO Lean Manufacturing

15 Reduced material!wastage and errors High Quality Technical Plastic Components For Automotive, Medical and Electrical Industry It costs money to have the wrong number of parts. Even too many parts create incremental labor cost, since the surplus parts have to be returned, stored, recycled or disposed. Technique Plastique uses METTLER TOLEDO counting scales in order to have always the exact number of parts at the right place. The Dutch company Technique Plastique was founded by its general manager Wim Kneepkens in The ISO certified company is specialized in plastic injection moulding of complex parts and in assembling of modules made of those parts for construction-, medical-, automotiveand electrical industries. A high degree of reliable automation of the material-flow is implemented. Several process steps like storage silo, drying, coloring, inject/ mould, eject, box-filling-and-sealing and palletizing are highly automated. Mr. Kneepkens proudly explains: "Pick and place robots and manipulators assure that the products are correctly taken out of the mould and transported to the correct storage". But Technique Plastique is not limited to production. The company supports its customers in developing its mould products. In Mr. Kneepkens words: "Together with the customer, we develop a solution. We engineer the high quality moulds from the idea to the design and test run until it is ready for serial production. Thanks to the high level of expertise within our company, we are able to serve customers with quality throughout the process from product-development to production. We also advise our customers in the efficient use of raw materials and additives. The task for our team is to continuously control and improve the process-steps". Technique Plastique relies on METTLER TOLEDO counting-scales in the production and packaging area to assure the right quantities. METTLER TOLEDO bench scales with a range of 60 kg are used for counting the right batch-quantities into the boxes and containers. Two recently installed countingscales IND435-BB35 help to manage the material-flow to the customer. Many produced plastic parts are assembled to modules in-house. For an efficient operation, it is essential that the assembly department receives the correct quantities of the individual parts. Shortage and surplus will both result in additional materialcosts and loss of labour-time. Mr. Kneepkens concludes: "The accuracy of METTLER TOLEDO counting scales optimizes our efficiency. They assure that exact quantities are available in the right place and at the right time". Always the exact number of parts at the right place METTLER TOLEDO Lean Manufacturing 15

16 A Worldwide Network of Experts at Your Service Thousands of manufacturers rely on qualified and equipped METTLER TOLEDO professionals to provide timely local and personal service. We make sure your measurement processes deliver required results. We combine our knowledge of industry regulations and applications with the broadest range of equipment and experienced professionals to provide high-value products and tailored service solutions that meet your needs. We base your satisfaction on three pillars: Consulting: We support you in determining the best solution for cost-efficiently maintaining production, quality and regulatory requirements. We can provide application analysis, equipment selection, project planning and management, training and maintenance program consultation. Solutions: We are the one source for all of the products, software, engineering and systems needed to meet your specific requirements to reduce wastage and speed-up production processes. Services: Whether you need to meet ISO 9001, ISO or other industry requirements, METTLER TOLEDO delivers. From calibration and minimum weight determination to equipment qualification, computer systems validation and preventative maintenance, ServiceXXL tailored services ensure uptime and compliance. For more information Mettler-Toledo AG CH-8606 Greifensee Tel Fax Subject to technical changes 02/2010 Mettler-Toledo AG