Efficient production processes at Reichenbacher Apparatebau

Reichenbacher Apparatebau GmbH is a family-owned company with a long tradition in thin sheet metal construction. The company has specialised in thin sheet metal construction since 1945. After the war, the company initially produced roof gutters and milk cans, and then developed steadily via a tinsmith’s shop. The company now employs 70 people. Among its customers is the world market leader for dentist’s chairs. Components for about 340 dentist’s chairs are produced in Lautertal every week, but the company also manufactures parts for the automotive industry, agriculture, submarines and the ESA. The company offers everything from a single source – from the idea to design, prototype construction, series production, final assembly and packaging. The skilled workers are trained right from the start. Training is particularly important to the company. A large number of the regular employees started as trainees. In addition to construction mechanics specialising in thin sheet metal construction technology, the company also trains industrial clerks and office management assistants.

Clearly structured warehousing

Reichenbacher Apparatebau works with RAJA products for the packaging of the products, for the dispatch as well as for the support of the smooth production processes. Open fronted storage bins in 3 different colours are integrated into the production process and are used for production materials. Each colour is assigned to a material:

• Red for stainless steel
• Blue for steel
• Orange and black for various types of plastic.

This colour code applies to the entire company. Every employee, including trainees or new employees, can quickly find their way around thanks to this simple visualisation. The processes are thus greatly simplified and clear stock management is made possible.

Stacking containers in the Kanban system

In addition, Reichenbacher Apparatebau uses stacking containers in 3 different sizes in production. Prefabricated parts are stored in the barcoded boxes in the paternoster warehouse in a space-saving manner and can be made available again accordingly quickly. Just-in-time delivery for the respective customer can thus be achieved. This form of storage saves about 80 % of the space compared to storing the pure raw material, as the prefabricated parts can be stored flat.

The stacking boxes from RAJA are thus part of the innovative Kanban system used by Reichenbacher Apparatebau. This system works according to the pull principle to control the flow of materials and is oriented to the actual consumption of materials within the production process. The process is fully automated. Depending on demand, the number of kanbans is automatically provided in the paternoster via the respective kanban card with barcode, which contains all important information. One kanban corresponds to one production order. At Reichenbacher Apparatebau, the stacking containers serve as load carriers for the kanbans. The required parts are made available in the stacking containers directly from the paternoster for further processing, for example for surface finishing. The advantages of this system: overproduction or limited stocks are avoided, delivery times are shortened and delivery reliability is increased. In production, throughput times are increased, the planning and control effort as well as the required storage space are reduced and there is a considerable increase in productivity in the entire procurement and control process.