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Lean manufacturing

Lean manufacturing – equipment for lean workstations, material flow and 5S

Lean manufacturing is a way of running production that eliminates waste – unnecessary handling, waiting for material and searching for tools. Enprag supplies modular systems made of steel tubes and aluminium profiles, ready-made structures and visual management for it: workbenches with a load capacity of 100–350 kg, crate rack trolleys, roller and gravity conveyors for KLT containers. The category is intended for production and assembly plants that want to introduce lean gradually, one workstation at a time. more
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Assembly and completion line with roller conveyor Code: 22042203

The assembly and completion line with roller conveyor is a modular solution designed for efficient production and smooth material flow between individual operations. The combination of workstations and a conveyor enables a logical process layout, reduces downtime and speeds up the handling of components. Each workstation is designed with a focus on clear organization and ergonomics. Material is available directly at the point of use, minimizing unnecessary operator movements and increasing overall productivity. The line is built using a modular pipe system, making it easy to adapt to specific production requirements, modify the layout or add further workstations. A suitable solution for assembly and completion processes where efficiency, clear organization and flexibility are essential.

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Packing and completion line with conveyor Code: 25080450

The modular packing and completion line is designed to ensure a smooth material flow from preparation through to dispatch. The workstation combines ergonomic workbenches, material supply racks and a roller conveyor that enables efficient transfer of finished products between individual operations. Thanks to its modular design, the line can be easily adapted to the specific process, product type and available production space. The solution helps reduce handling times, improve workplace organization and increase the productivity of packing operations.

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Linear assembly line with conveyor (One Piece Flow) Code: 25070201

The modular linear assembly line with conveyor is designed to ensure a smooth material flow between individual operations. The workstations are arranged in sequence, enabling an efficient progression of production steps and minimizing unnecessary handling. The line combines ergonomic workstations, clearly organized component supply racks and an integrated conveyor for smooth product transfer. Thanks to its modular design, the solution can be easily adapted to the specific process, type of production and available space. It helps reduce production times, improve workplace organization and support lean manufacturing principles such as One Piece Flow and material flow optimization.

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Assembly line with retractable ball transfer system and locking mechanism Code: 26031230

The assembly line with a retractable ball transfer system and locking mechanism is a modular solution designed for smooth material flow and ergonomic operator work. The workpiece is moved to the workstation on ball transfer units. A simple locking mechanism allows the balls to be lowered below the level of the work surface. The product then rests securely on the worktop and is ready for production or assembly operations. Once the operations are completed, the balls are raised above the work surface again, allowing the product to be easily moved to the next workstation without lifting or demanding manual handling. The solution supports a smooth production flow, improves workplace ergonomics and reduces physical strain on the operator. The line is built using a modular aluminium profile system, allowing its configuration to be adapted to specific production requirements and changing operational needs. The solution is suitable for production and assembly processes where smooth production flow, workplace ergonomics and flexibility are important.

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In stock
Guide for roller track PA-403C Code: PA-403C

Guide for roller track PA-403C, length 4000 mm, plastic design. Width 46.2 mm, weight 640 g/m.

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In stock
Guide for roller track PA-412B_3m Code: PA-412B_3m

Guide for roller track PA-412B, length 3000 mm, plastic design. Width 87 mm, weight 906 g/m.

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In stock
Guide for roller track PA-412B Code: PA-412B

Guide for roller track PA-412B, length 4000 mm, plastic design. Width 87 mm, weight 906 g/m.

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In stock
Guide for roller track PA-404D Code: PA-404D

Guide for roller track PA-404D, length 3000 mm, plastic design. Width 47 mm, weight 824 g/m.

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In stock
Aluminium Guide Rail PA-405E Code: PA-405E

Guide for roller track PA-405E, length 4000 mm, aluminum design. Width 27.8 mm, weight 1688 g/m.

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In stock
Guide for crates WG-0430 Code: WG-0430

Guide for crates WG-0430, length 430 mm, steel design. Width 70 mm, weight 280 g.

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In stock
Protective cover for tubes TH-0001 Code: TH-0001

Logiform pipe cover, PVC with protective fabric, total length in roll 45 m, sold by 1 m.

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In stock
Protective cover for tubes TH-0002 Code: TH-0002

Logiform pipe cover, transparent PVC, total length in roll 45 m, sold by 1 m.

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In stock
Metal sleeve MT-5110 Code: MT-5110

Metal sleeve MT-5110, weight 66 g.

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In stock
Metal sleeve MT-5111 Code: MT-5111

Metal sleeve MT-5111, weight 20 g.

Lean production in practice: workstations, material flow and 5S

Lean manufacturing eliminates waste in production – unnecessary carrying, waiting and searching. Enprag builds workstations, racks and conveyors for it from modular systems: tables from the range carry 100–350 kg, custom tables are typically designed for up to 500 kg and trolleys for up to 1 t. Height-adjustable frames offer an adjustment range of up to 650 mm. A structure can be dismantled and rebuilt at any time, so you can introduce lean step by step without rebuilding the entire plant.

Lean methods: how to support 5S and Kanban?

The 5S method needs a fixed place for every tool: Enprag workstations are fitted with panels for organising tools and material, swivel arms, monitor holders or lighting, and can be delivered including electrical installation. For Kanban and process visualisation, Enprag designs suitable boards – you will find them in the visual management category. An example of a complete workstation is the electric height-adjustable workstation 24111933 with an extension, a working height of 700–1350 mm and a load capacity of 250 kg.

How to ensure continuous material flow between workstations?

Continuous material flow is most often achieved with gravity or powered conveyors. Flow racks with roller tracks ensure FIFO picking at a standard slope of 3°; return lanes for empty containers are placed above or below the picking level. KLT containers are moved between stations by the crate rack trolley SP10040 with 5 inclined shelves of 60 kg each; trolleys can be coupled into a tugger train of up to 5 trolleys.

Production layout optimisation: tubes or aluminium profiles?

The pipe modular system suits applications that need versatility and easy reconfiguration; aluminium profiles from 30×30 to 45×90 mm carry higher loads and handle more demanding operation. Both systems can be combined in one assembly. Structures are designed for a maximum deflection of 5 mm, and for tall racks and trolleys the width-to-height ratio is at most 1 : 3.

Lean manufacturing equipment by type (Enprag)
Equipment type Load capacity Key parameters Example model
Workshop and packing tables 100–350 kg width 1200–2000 mm Packing table 24020580
Height-adjustable tables 150–300 kg height 650–950 mm Enprag SPEX127, 22112841
Electric height-adjustable and ESD tables 250–300 kg height 680–1350 mm, 3-position memory 24111933, 25080742
Crate rack trolleys and shelf racks 300 kg 5 shelves of 60–75 kg, Ø100 mm castors SP10040, 22110350
Roller and gravity conveyors per assembly roller lanes for KLT containers built to your layout

Do you want to introduce lean manufacturing at your workplace? A photo or sketch with dimensions and load capacity is enough for the first design; the structural design and 3D visualisation are free of charge and are sent for your approval before the quotation. Contact Enprag.

Frequently asked questions

Where should you start with implementing lean manufacturing?

With one workstation or one section of the material flow. Enprag sales engineers visit your plant, measure the structure on site and deliver a new layout design including 3D models of the applications free of charge – a photo or sketch with dimensions is enough for the first design.

Does lean manufacturing also help small companies or one-off and small-batch production?

Yes. Enprag modular systems are also suitable for prototypes – once tested, a series can be produced, and when production changes, the structure can be rebuilt using the original components. Material is in stock for delivery within a few days, complete assemblies usually within 2–4 weeks.

Can lean manufacturing be introduced gradually, starting with one workstation?

Yes, Enprag recommends starting with a pilot project at 1 workstation and gradually extending the solution. Thanks to archived 3D models, the structure can later be rebuilt at minimal cost, replacing only damaged parts rather than the whole assembly.

How do modular systems help with 5S and Kanban?

Enprag workstations are fitted with panels for organising tools and material, flow racks with roller tracks at a 3° slope ensure FIFO picking, and Enprag designs suitable boards for Kanban. When the process changes, the assembly is rebuilt without a new investment in the entire workstation.

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