BT at Poclain Hydraulics manufacturing plant, Verberie, France.
3 BT LST 1350 trucks have become an integral part of the assembly process. Patrick Daime, plant manager explains how and why.
Leakproof testing done without dismounting the finished motor.
Question: Patrick, who is Poclain Hydraulics?
Patrick DAIME: Poclain Hydraulics is the leader in hydrostatic transmissions. We design innovative products and systems for the mobile industry. The plant I’m in charge, in France, manufactures valves and the larger frame size for the low speed high torque motors. These motors have a displacement between one (1) and fifteen (15) litre/rev. They weigh between sixty (60) and six hundred (600) kg. Assembly and handling of these products, made parts machined to the micron, for some of them, is a challenge in it self.
Q: This mobile work station attached to a fork lift truck is very original. Isn’t it?
PD: We have a very long tradition of innovation. It is obvious on the products we create but we also have been innovating on the production side because we have always been manufacturing products that did not exist before. Therefore, since no product was matching the need, we invented it.
Q: How is it done?
PD: We developed a special attachment to the standard truck. It includes a rotatable bracket to hold the motor throughout the entire assembly process and a special oil spilling recovery floor to keep the factory clean.
Q: Who designed it?
PD: We did, with help from the operators, who brought their ideas to improve efficiency and working conditions. They are the ones working on the machines 8 hours a day, not the engineers. The Safety and Environment Department helped as well.
Q: Why did you choose to develop these mobile workstations?
PD: We had to replace a twenty years old automatic guided system that started to require heavy maintenance. It was an opportunity to improve our flexibility, safety, productivity and reliability. We can now, on demand, triple the output with our three mobile work stations. In nowadays industry, pace is given by the customer. “Tak” time (demand frequency) has become our clock; we have to adapt.
Q: This is impressive. How is this possible?
PD: Compared with the old system, we gained autonomy of production for each of the three workstations. We have no longer a train track where the slowest machine sets the pace. Plus, with the handling capacity of the truck, we cancelled two dismounting/mounting actions. In the past the finished motor had to be taken off twice for each test (air pressure and oil pressure) before delivery to the painting area. Plus, if test failed, it had to be remounted back to the assembly line at square one. Now, both tests are done on the assembly brackets. Today, the operator produces his own motor from elementary parts and is responsible for delivering a tested and working product. Their responsibility, involvement and competence have increased, same for the work purpose.
Q: Why did you choose BT?
PD: First, we wanted to work with a leading company. Second, we have been using BT reflex warehouse trucks for many years and we like the way they drive, like a hydrostatic transmission (laughs!). Furthermore, we appreciate the reliability of the product and the reactivity from the service department. Our relationship is good and we look for long term commitment with our suppliers.
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All pictures © Eric Blondeau