Lean pipe workbench/Assembly line

Lean pipe workbench/Assembly line

Lean tube workbenches, also known as flexible tube workbenches or composite tube workbenches, are modular workstation fixtures designed according to the principles of Lean Production. Featuring a core framework of lean pipes (composite tubing with an outer PVC resin layer, metal alloy core, and rust-proof inner coating), these workbenches utilise standardised components such as connectors, panels, castors, and lighting. Their flexible assembly and rapid reconfiguration address production floor requirements for workstation adaptability, efficiency, and cost-effectiveness. Widely deployed across electronics, automotive, machinery, logistics, and other manufacturing and warehousing sectors, they deliver tailored solutions for diverse operational needs.

Structural Composition

Overall Framework:

Composed of standard flexible wire rods with an external diameter of 28mm and wire rod connectors. Flexible wire rods are available in multiple colours including beige, white, and black. Wire rod metal connectors include silver-white chrome-plated joints and black electrophoretic joints.

Feet:

Adjustable foot cups may be employed, such as height-adjustable cups, anti-vibration cups, conductive cups, or anti-static cups. Alternatively, castors may be used, including flat-plate castors or expandable castors.

Worktop surfaces:

Options include composite panels, fire-retardant boards, ESD anti-static panels, multi-layer plywood, stainless steel sheets, and hollow-core panels.

Additional accessories:

These encompass lighting systems (e.g., fluorescent tubes, independent switches, power strips, wiring); logistics systems (e.g., conveyor belts, sliding rails, turntables, robotic arms); alongside drawers, electric screwdriver slots, process flow guides, and warning lights.

Features

1.Flexibility:

Rapid adaptation to production changes

Without specialised tools, workbench dimensions (e.g., length, height) and configurations (e.g., adding shelves, extending worktops) can be adjusted within 1-2 hours by swapping connectors or adding/removing lean tubes.

Example: When an electronics factory switches from ‘mobile phone assembly’ to ‘tablet assembly’, only the workbench height needs raising and side shelves added for storing large-screen components – no new equipment procurement required.

2. Low Cost:

Reduced Investment and Maintenance Expenses

Low material cost: Lean tubes and connectors are significantly cheaper than traditional steel workbenches and are reusable (disassembled units can be reconfigured into new workstations);

Low maintenance costs: Should individual components fail (e.g., connector breakage, worktop scratches), only the affected part requires replacement, avoiding complete disposal;

Case study: An automotive parts manufacturer reduced new workstation setup costs by 40% compared to conventional workbenches by reusing existing lean tubes.

3. Efficiency:

Optimising operational workflows

Ergonomic compliance: Workbench height adjustable to operator stature (standard 75-85cm, customisable for special scenarios), minimising unnecessary bending or arm elevation to reduce operator fatigue;

Material ‘proximity principle’: Frequently used tools/materials positioned within arm's reach via hanging panels and racks, shortening retrieval time and enhancing operational efficiency (statistically reducing material handling time by 15%-20%); .

4. Safety:

Ensuring operational security

Anti-static properties: The combination of anti-static lean tubes, anti-static worktops, and grounding wires effectively dissipates static electricity, preventing damage to electronic components (particularly suitable for semiconductor and electronics industries);

No sharp edges: PVC-coated tubing with rounded connectors prevents cuts during operation;

Stability: Properly configured systems support 300-800kg loads (frame-dependent), while braked castors prevent movement.

5. Manageability:

Visualised organisation

Modular construction enables orderly workstation layouts and categorised material storage (e.g., labelled bins), facilitating on-site 5S management (Sorting, Straightening, Sweeping, Standardising, Sustaining).

Compatible with signage and production boards to display real-time workflow and output targets, enhancing operational transparency.

Application Scenarios

Core Manufacturing Scenarios

Electronics and Electrical Industry:

PCB assembly benches, chip testing stations, mobile phone/computer component assembly stations (requiring anti-static properties and lightweight construction);

Automotive and Components Industry:

Automotive wiring harness assembly benches, engine sub-assembly stations, after-sales maintenance workstations (requiring impact resistance and mobility);

Machining Industry:

Small component grinding stations, mould debugging auxiliary stations, gauge calibration stations (requiring high-strength worktops).

2. Warehousing and Logistics Scenarios

Warehouse picking workstations:

Equipped with shelving and material bins for order picking and goods verification;

Logistics packaging stations:

Mobile design facilitating integration with production lines, featuring weighing modules and packaging material racks.

3. Specialised Industry Applications

Food/Medical Sector:

Stainless steel worktops for food sorting and medical device assembly (requiring disinfection resistance and corrosion protection);

Laboratory Settings:

Anti-static, corrosion-resistant surfaces for precision instrument operation and sample testing (requiring exceptional stability).

Summary

The lean tube workbench centres on the principles of modularity, flexibility and low cost. Through the free combination of standardised components, it achieves the lean objective of ‘workstations adapting to production demands’. It serves not only as an operational platform on the shop floor but also as a vital tool for enterprises to advance 5S management, enhance production efficiency, and reduce operational costs. Particularly suited to businesses operating under a multi-variety, small-batch production model, it stands as one of the fundamental workstation tools for modern manufacturing's lean transformation.