Case study

Assembly lines balancing

A company assembling plastic parts approached us with a request to improve their work organisation and reduce the wasting of production resources. The changes that we implemented have contributed to achieving an optimal output (reflecting customer takt) and to reducing rework and inventory.

01

Challenges

The customer's pain points and needs

  • high manufacturing costs
  • high scrap rate at the workstation
  • variable assembly line output
  • overproduction and high inventory
  • bad ergonomics of the working procedure
02

solution

Based on an initial analysis, we proposed the following solution:

  • adjusting the production line layout
  • implementation of low-cost automation, elimination of unproductive tasks
  • adjusting production to match customer takt
  • clear definition of the working procedure, implementation of poka-yoke mechanisms in the manufacturing process
03

results

A selection of achieved improvements

0 %
higher productivity
0 %
lower inventory of defined products
0 %
less rework
0
operator hours saved monthly

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