But all of that changed when Branson developed its new Bransonic Series family of benchtop ultrasonic cleaners, for use in cleaning medical instruments and jewelry. In a break from the past, Branson involved its manufacturing engineering department in the project from its inception. Ease of assembly was included in the product design criteria, along with factors such as parts count reduction, and total quality procedures. A team headed by Walt Kohler, Branson’s manager of advanced manufacturing process development, was given a clean slate for creating a Just-In-Time (JIT) assembly cell to replace the traditional batch assembly line system. The goal was development of a world class manufacturing operation.
Branson’s specific objectives included a reduction of work-in-process (WIP) by at least 50%. The team also aimed to increase throughput via the adoption of a one-piece flow system that would include on-line testing and packaging. A significant reduction in non-productive labor, elimination of excessive lifting, and improved ergonomics were also on the list.