Optimizing assembly lines results in productivity and significant savings in time and production costs, while ensuring high and stable levels of quality.
Here are some tips for optimizing assembly lines.
a) Review the concepts used for assembling and designing an effective layout
Depending on the type of products to be assembled it can be more convenient an assembly line in constant line, other flexible either by cells, among other alternatives. If assemblies are easy to handle and are not too many, what might function are work cells, but if it were heavier elements, flexible lines would be most suitable.
Regardless of the concept in question, the design of a fluid and consistent scheme in loads per operator, who inserts quality components to reach expected product or by product, is essential.
Efforts should be made to walk distances are minimal, so that the product goes to the operator and not vice versa. Most of the time, for this use, AGC systems are utilized; trying to execute operation always in an ergonomic way and it is endowed with the right devices for handling. For example, in the automotive parts industry it is very common the implementation of VLM (Shuttle) systems which facilitate such operations.
There are various methods of balancing workloads simply do whatever it takes for asset standard times with quality and safety.
b) Balance the production of the side processes at assembly
The assembly lines conjoin previously manufactured components, some internally and others externally acquired. Whatever be the case, they must be stored or produced in the right amounts to not drive over- stock or stop the flow of production and assembly.
If the assembly line is very efficient, but the technical elements of rolling are not included, it ends up being an ineffective line. You must ensure, in coordination with industrial engineering, the favorable rates to achieve a harmonious whole. To achieve this, remember that you can count on IT tools and MES to handle all the logistics inside effectively and efficiently.
c) Check the standard times of operations
Establish an annual routine to review standard time on which you base your schedule. Over time, certain processes are optimized or changed, causing inefficiencies with general workers operating at a low rate.
It can also happen that some machines become deteriorated and become a habit to do things at a slower pace, instead of fixing the root problem. What is recommended in these cases is to analyze and compare the times of the various processes with preset times or international ones. What you do not measure, you cannot control.
d) Create a productive environment
If you are looking for increased productivity without sacrificing quality, in an environment where labor as the primary ingredient is involved, creating a productive atmosphere, incorporating breaks with some physical activity, provide a suitable room and even play music when it is prudent, are actions that positively impact both concepts: productivity and quality.
The concept of quality build is more relevant than control it. With well aware and staff knowledgeable of measures by standards, it will be seen clear increases in productivity and quality. So remember to provide the security, protection and comfort that requires your staff.
e) Standardize, improve and automate
All processes must be respected and standardized, working with attachment to them, or, if it is possible, improve them. Stay tuned for opportunities to improve your current processes and once optimized, standardized them. Remember to automate processes that demonstrate a healthy return on investment.
In GIEICOM we provide intelligent logistics solutions to automate and redesign assembly lines in order to make them more productive and effective.
