Reconfiguration of assembly lines using lean thinking in an electronics components' manufacturer for the automotive industry

Abstract

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 There were three main distinct problems related with the outdated assembly lines.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.