Lean Assembly: The Nuts and Bolts of Making Assembly Operations Flow

Front Cover
CRC Press, Oct 2, 2002 - Business & Economics - 296 pages
With examples drawn from aerospace, electronics, household appliance, personal products, and automotive industries, Lean Assembly covers the engineering of assembly operations through:

  • Characterizing the demand in terms of volume by product and product family, component consumption, seasonal variability and life cycle.
  • Matching the physical structure of the shop floor to the demand with the goal of approaching takt-driven production as closely as possible.
  • Working out the details of assembly tasks station by station, including station sizing, tooling, fixturing, operator instructions, part presentation, conveyance between stations, and the geometry of assembly lines as a whole.
  • Incorporating mistake-proofing, successive inspection, and test operations for quality assurance.

    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.

 

Selected pages

Contents

Figures
1
Figures
8
Tables
11
Product quantity analysis
15
FIGURE 23 Number of items common to pairs of products
24
Trend and seasonality analysis
27
TABLE 31 Weighted aggregate workload calculation
31
FIGURE 36 Finished goods inventory profile with production based
37
FIGURE 91 Large station for small product
129
FIGURE 98 Access to multiple sections in large product assembly
135
FIGURE 912 Curing station
141
Detailed design of assembly stations
143
FIGURE 103 Lazy Susan for flexible computer assembly
147
FIGURE 108 Tools attached to stations versus assemblers
154
FIGURE 1013 Assembly instructions for Knex Cybots
160
FIGURE 1014 Work combination chart for mechanized assembly
162

Takt time and capacity
41
FIGURE 44 Approximation of taktdriven production
47
TABLE 41 Typical takt times by industry
52
FIGURE 47 Operators working on batches of parts
53
PART B Assembly concepts
59
FIGURE 51 Shop floor blueprint
63
FIGURE 55 An assembly master table
69
TABLE 51 A comparison of material flow mapping symbols
72
FIGURE 57 An assembly cell layout drawing
76
The concept of the assembly line
85
FIGURE 61 The assembly line
86
FIGURE 64 A cell for cardiac monitor assembly in Japan
94
TABLE 61 Bench vs line with 100min process takt time 1 min
97
FIGURE 611 Modular assembly for the Smart car in Hambach
100
Collecting assembly time data
103
FIGURE 71 Physical load degree
110
Line balancing
113
FIGURE 81 The principle of assembly line balancing
116
FIGURE 82 Steps to rebalancing a dedicated line
117
TABLE 81 Batch versus level sequencing in multiproduct lines
120
FIGURE 84 Catching up in a deliberately imbalanced line
123
Detailed design
125
FIGURE 1019 Stop ropes and andon boards
168
Part presentation
171
FIGURE 113 Net effect of adding a picker
174
FIGURE 119 The orientation dilemma
180
FIGURE 1114 An example of a kit pallet
186
Conveyance between stations
193
FIGURE 121 Spiral conveyor system
194
Assembly cells
201
FIGURE 131 A Ushaped assembly cell
204
FIGURE 135 Three ways of supplying parts to an assembly cell
207
Overall shape of assembly lines
211
FIGURE 142 Snaking assembly line
213
FIGURE 148 B24 assembly line at Willow Run Michigan during
220
Assembly quality
221
FIGURE 151 Auto ID technologies used in manufacturing
227
FIGURE 156 Mistakeproofing using a fliplid approach
233
FIGURE 1511 Approaches to warehouse visibility
240
Inspection test and rework operations
243
FIGURE 161 Sample pooling for blood testing
255
FIGURE 164 Offline rework station
261
Bibliography
263
Copyright

Other editions - View all

Lean Assembly: The Nuts and Bolts of Making Assembly Operations Flow
Michel Baudin
Limited preview - 2020
Lean Assembly: The Nuts and Bolts of Making Assembly Operations Flow
Michel Baudin
No preview available - 2020

Common terms and phrases

approach assem assembly cell assembly fixture assembly line assembly master tables assembly operations assembly process assembly station auto ID automatic automatic test equipment automation batch bench assembly bins buffers bullwhip effect components conveyance system conveyor defective demand dunnage electronic engineers example factories feeder lines figure of merit final assembly line finished goods inventory fixture Tools floor flow rack improvement industry instruction sheets item numbers kits large products lean manufacturing line design line side load logistics machine manual assembly material flows minutes mistake-proofing mixed-flow line moving multiple orientation P-Q analysis pallet plant Printed circuit boards product family product units Production monitor replenishment requires RFID segments shift Shigeo Shingo shown in Figure shows single-piece presentation subassembly supermarkets suppliers supply chain takt takt-driven production tasks tion Toyota transportation aisle TVAL U-shaped cells upstream value stream mapping water spiders

References to this book

About the author (2002)

Michel Baudin (MMTI, Palo Alto, California, USA) (Author)

Bibliographic information

TitleLean Assembly: The Nuts and Bolts of Making Assembly Operations Flow
AuthorMichel Baudin
Editionillustrated
PublisherCRC Press, 2002
ISBN1563272636, 9781563272639
Length296 pages
Subjects › 

Business & Economics / Quality Control
Technology & Engineering / Manufacturing
  
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