Publicação
Reconfiguration of assembly lines using lean thinking in an electronics components' manufacturer for the automotive industry
| Resumo: | This article discusses the reconfiguration and improvement of electronics components assembly lines through the use of Lean Thinking principles. This reconfiguration was undertaken in a project that followed the action-research methodology. There were three main distinct problems related with the outdated assembly lines. The first came from a diagnosis of the assembly line itself, where quality problems and difficulties with compliance with the takt-time were identified, as well as activities that do not added value. The second happened due to an adjustment in demand that requires a reconfiguration of the line and, the third problem, related to the integration in an existing assembly line of a new process for a product pertaining to the same family, forcing the exploitation of synergies in production of these two products. Regarding the improvement proposals, some managed to be implemented in a timely manner, others, despite not having been implemented, their impacts has been predicted. Overall, the level of scrap was reduced by 57% through the implementation of the Lean Six Sigma methodology, and the cycle time of an operation was reduced by 12,5% by eliminating non-value adding operations. Also, gains were obtained by reducing the previous occupation with the project of an assembly line segment dedicated to the new product. With this, a reduction of one employee with the integration of two workstations was achieved. |
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| Autores principais: | Bastos, N. M. |
| Outros Autores: | Alves, Anabela Carvalho; Castro, F. X.; Duarte, J.; Ferreira, L. P.; Silva, F. J. G. |
| Assunto: | Automotive components Lean thinking Lean six sigma Reconfiguration of asssembly lines Automotive industry |
| Ano: | 2021 |
| País: | Portugal |
| Tipo de documento: | comunicação em conferência |
| Tipo de acesso: | acesso aberto |
| Instituição associada: | Universidade do Minho |
| Idioma: | inglês |
| Origem: | RepositóriUM - Universidade do Minho |
| Resumo: | This article discusses the reconfiguration and improvement of electronics components assembly lines through the use of Lean Thinking principles. This reconfiguration was undertaken in a project that followed the action-research methodology. There were three main distinct problems related with the outdated assembly lines. The first came from a diagnosis of the assembly line itself, where quality problems and difficulties with compliance with the takt-time were identified, as well as activities that do not added value. The second happened due to an adjustment in demand that requires a reconfiguration of the line and, the third problem, related to the integration in an existing assembly line of a new process for a product pertaining to the same family, forcing the exploitation of synergies in production of these two products. Regarding the improvement proposals, some managed to be implemented in a timely manner, others, despite not having been implemented, their impacts has been predicted. Overall, the level of scrap was reduced by 57% through the implementation of the Lean Six Sigma methodology, and the cycle time of an operation was reduced by 12,5% by eliminating non-value adding operations. Also, gains were obtained by reducing the previous occupation with the project of an assembly line segment dedicated to the new product. With this, a reduction of one employee with the integration of two workstations was achieved. |
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