Gestamp is an international group specialized in the design,
development and manufacture of highly engineered metal components
for top vehicle manufacturers. Over 40,000 employees. More than 100 plants in 24 countries.
The Gestamp Louny plant has a very innovative hot stamping facility. And also laser, welding and assembly operations. The plant supplies a wide variety of renowned automotive OEMs in Europe.
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VIDEO SUBTITLES
Carl Timmer, Plant Director Gestamp Louny (CZ):
'When I joined, in the end of 2018, GESTAMP Louny (CZ),
the plant has just gone through extensive growth.
The plant was losing its operational grip.
And when we looked into the business plan, there were still five years of growth ahead for GESTAMP Louny, about 30%.
One area, that was very clear, that we needed to work on, was logistics.'
Zdeněk Holcepl, Industrial Manager Gestamp Louny 2 (CZ):
'The second issue we had, was the downtime during the exchange of the boxes in the production line.
During this period, we were facing around 3% of downtime due to box exchange.'
Carl Timmer, Plant Director Gestamp Louny (CZ):
'Typical targets for the team were, to restore a detailed storage of materials, location management and good stock accuracy, FIFO.
To reduce the downtime, we were having from logistics on our cells in the plant.
And to eliminate as much as possible forklifts and the safety risk that was clearly visible in our plant.'
Heico Timmers, Owner – LMC LOGISTICS CONSULTANCY:
LMC LOGISTICS CONSULTANCY formulated the new logistics concept for GESTAMP Louny.
Three major basic points are in the concept.
First, all large load carriers are on trolleys.
Second, at the lineside in front of the welding and laser cells, we have two containers per reference.
And third, we shifted from a taxi-like material supply operation by forklifts to a busline-like operation by logistic trains.
LMC formulated the conceptual design for a new type of large train.
It consists of trailed frames, on which large trolleys, ranging in length from 1.8 m till 2.6 m, can be loaded and unloaded from both sides.
Furthermore, the trolley wheels are not on the floor during transport.
In this way, reducing noise and wear.
This conceptual design was engineered and detailed further by the company STILL.
Eventually, this gave the new STILL P-frame, that is operational at GESTAMP Louny now.'
Jaroslava Hanišová, Logistics Manager Gestamp Louny 2 (CZ):
'We were able to completely remove all forklifts from the most critical production in Business Unit 3.
For the other parts of production, we eliminated the forklifts and minimized the material flow.
The material is placed close to the workstation. And the forklift doesn’t need to go far away for the material.
That’s why we were able to eliminate the downtimes and also the safety risks.
We had to be sure, that the trains will handle all material in time, and we wouldn’t cause any downtimes.
Therefore, we had detailed calculations about all train routes and all handling, which is supposed to be done.'
Michal Moravec, Warehouse Manager Gestamp Louny 2 (CZ):
'During the implementation phase, we created a handbook for new employees.
So, the training is currently only one week.'
Zdeněk Holcepl, Industrial Manager Gestamp Louny 2 (CZ):
'There is not any reason to rush now, because we have 30 minutes to replace the box.
And if any downtimes occur in the production, it is mainly in some non-conformity in the material flow.'
Jaroslava Hanišová, Logistics Manager Gestamp Louny 2 (CZ):
'STILL is a very flexible company.
They supported us during the P-frame development, and they helped us to make this project successful.'
‘Lukás Zach, Sales Manager STILL (CZ):
'In collaboration with LMC, Mr Timmers, we had a chance to integrate changes or new customer demands during the development phase of the project.
So, the complete project management with all involved parties was a real partnership.'
www.gestamp.com www.LMCnet.nl www.still.eu
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