Lean Assembly

by Baudin; Michel

• ISBN13: 9781563272639
• ISBN10: 1563272636
• Format: Hardcover
• Copyright: 2002-10-02
• Publisher: Productivity Pr

Summary

Lean Assembly differs from most other books on lean manufacturing in that it focuses on technical content as a driver for implementation methods. The emphasis is on exactly what should be done. This book should be the "dog-eared" and "penciled-in" resource on every assembly engineer's desk.

Table of Contents

Figures	p. xi
Tables	p. xvii
A guided tour	p. 1
Analysis techniques	p. 3
Key issues of assembly operations	p. 5
What is assembly?	p. 6
Scope of this book	p. 6
Assembly = assembly and test	p. 6
Factors in assembly performance	p. 8
Part supply	p. 8
Assembly work design	p. 9
Examples	p. 10
Waste in assembly work	p. 11
Recognizing waste in assembly work	p. 11
Eliminating assembly waste	p. 13
Product quantity analysis	p. 15
Purpose	p. 16
The concept of P-Q analysis	p. 17
Difference with Group Technology	p. 18
Bill of materials analysis for mixed-flow lines	p. 20
Order profiling for custom assembly	p. 25
Trend and seasonality analysis	p. 27
Purpose	p. 28
Responding to demand variability over time	p. 29
Data aggregation	p. 30
Making the sales data talk	p. 32
Demand variability upstream in the supply chain	p. 37
Conclusions	p. 39
Takt time and capacity	p. 41
What is the takt time?	p. 41
Definition of the term	p. 42
Design takt time and operation takt time	p. 44
Common mistakes about takt time	p. 45
Why takt time matters	p. 46
Global and local performance	p. 48
Takt time, labor requirements, and line design	p. 50
The minimum required number of assemblers	p. 50
Assembler job design issues with short takt times	p. 52
Assembler job design issues with long takt times	p. 55
Assembly concepts	p. 59
Visualizing the assembly process	p. 61
Needs and evaluation criteria for visualization tools	p. 62
The problem with facility blueprints	p. 63
Lists and assembly master tables	p. 67
Abstract flow diagrams and their limitations	p. 70
Layout diagrams with flows	p. 75
Two-dimensional diagrams	p. 75
Three-dimensional drawings	p. 78
Integration of text and drawings	p. 79
Photographs	p. 79
Impact of digital photography	p. 79
Shop floor photography guidelines	p. 80
Video recordings	p. 81
Cardboard mock-ups	p. 81
Discrete-event simulations	p. 82
The concept of the assembly line	p. 85
What is an assembly line?	p. 86
Bench assembly versus the assembly line	p. 87
Why assembly lines are still controversial	p. 88
Comparing bench assembly with line assembly	p. 89
Exceptions: where the bench still wins	p. 92
Assembly lines, assembly cells, and line segments	p. 93
Assembly and subassembly	p. 97
All assembly work done in one single line	p. 97
Final assembly line with subassembly feeder lines	p. 98
Modular assembly	p. 99
Pros and cons of subassembly/feeder lines	p. 101
Collecting assembly time data	p. 103
Why this needs attention	p. 103
Data collection methods	p. 104
Current status of time and motion studies in manufacturing	p. 105
Predetermined time standards in the automobile industry	p. 105
MTM and MOST	p. 107
Time studies with video recordings	p. 111
Line balancing	p. 113
Assembly line balancing	p. 114
Rebalancing a dedicated line	p. 115
Multiproduct lines with batch versus leveled sequencing	p. 119
Balancing assembly time among products on a mixed-flow line	p. 121
Deliberate imbalances	p. 122
Detailed design	p. 125
Assembly station sizing	p. 127
Issues with assembly station sizing	p. 128
Assembly stations for small products	p. 128
Assembly stations for large products	p. 132
Ergonomics and safety	p. 136
Standing versus sitting	p. 136
Work height and assembler height	p. 139
Stations with required dwell times	p. 140
Detailed design of assembly stations	p. 143
Issues with assembly station details	p. 144
Assembly fixtures	p. 144
Fixtures for manual assembly	p. 144
Fixtures for mechanized or automated assembly	p. 149
In-line mechanical automation	p. 151
Handheld tools	p. 152
Tools attached to the station and not to the assembler	p. 152
Tool positioning and orientation	p. 154
Assembly instructions	p. 157
Instruction sheets	p. 157
Contents of instruction sheets for manual assembly	p. 158
Content of instruction sheets for mechanized assembly	p. 161
Instruction sheets for mixed-flow assembly	p. 162
Authoring instruction sheets	p. 163
Use of information technology	p. 163
Visible management	p. 164
Self-explanatory devices, markings, and color codes	p. 164
Tower lights, stop ropes, and other types of andons	p. 166
Counters and production monitors	p. 168
Part presentation	p. 171
Scope and purpose	p. 172
Part presentation requirements	p. 172
Controversies about part presentation	p. 175
Key principles of part presentation	p. 176
Removal of packaging materials before delivery	p. 176
Location within arm's reach of the assembler	p. 178
Orientation	p. 179
Adjustments to specific part characteristics	p. 181
Matching quantities	p. 182
Containers with dunnage for counting	p. 184
Kitting versus line-side supply	p. 185
Single-piece presentation and water spiders	p. 186
Single-piece presentation	p. 187
Water spiders and supermarkets	p. 189
Conveyance between stations	p. 193
Issues with conveyance systems	p. 194
Goals for the conveyance system	p. 196
A few types of conveyance systems	p. 197
Unpowered conveyance	p. 197
Powered conveyance	p. 199
Assembly cells	p. 201
About assembly cells	p. 202
The motivation for cell conversion	p. 203
Part supply to assembly cells	p. 206
Range of applicability of the U-shape	p. 208
Pseudo U-shaped cells	p. 210
Overall shape of assembly lines	p. 211
Beyond cells	p. 211
Car and related assembly lines	p. 212
Airplane assembly lines	p. 218
Assembly quality	p. 221
Preventing picking errors	p. 223
About this chapter	p. 224
Mistake-proofing assembly operations	p. 225
Approaches to automatic identification	p. 226
Using kit pallets and product fixtures to prevent mistakes	p. 228
Mistake-proofing lineside picking	p. 231
Mistake-proofing the kitting process	p. 235
From stores to the line	p. 237
Storage and retrieval	p. 238
Naming items to avoid confusion	p. 240
From the supplier to the dock	p. 242
Inspection, test, and rework operations	p. 243
The issues of inspection, test, and rework	p. 244
The literature	p. 246
The quality control literature	p. 246
The lean manufacturing literature	p. 246
The general literature on assembly	p. 247
Is self-inspection possible?	p. 247
Inspection and test sequencing	p. 249
Sequencing by decreasing figure of merit and its limitations	p. 250
Sequencing by induction	p. 252
Testing multiple units at once	p. 254
Designing automatic binning operations	p. 256
Rework operations	p. 257
Self-inflicted rework	p. 258
Rework operations	p. 259
Bibliography	p. 263
Books in English	p. 264
Books in Japanese	p. 265
Books in German	p. 265
Books in French	p. 266
Index	p. 267
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