Worksmart Systems Lean Assembly Road Map in 7 Mile Markers
Here’s a road map with some observations. This is a compilation of some of the successful points which we have implemented in our years of developing and building successful, efficient, lean assembly cells. If you would like to obtain a copy, please follow the link to our site at the end.
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Mile #1 - "Goals and Initiate"
“The journey of a thousand miles begins with a step.”
- CREATE TEAM
- NEW OR EXISITING PRODUCT
- PROGRESSIVE ASSEMBLY
- PRODUCTION PROJECTIONS
- DEVELOP TAKT TIME
- KANBAN
- MIXED OR SINGLE MODEL
- ON-LINE TEST
- PACK OUT
- KAIZEN CONCEPT
Mile #2 - "Review Process"
Analyze the process and simplify wherever possible.
“Plan your work and work your plan”
- ESTABLISH BENCHMARKS
- CREATE ASSEMBLY STEPS
- DEVELOP LAYOUT
- DIVIDE WORK CONTENT
- INCORPORATE NON ASSEMBLY WORK IE: TEST, QC, PACK
- CREATE BUDGET
- COST BENEFIT ANALYSIS
- SIMPLIFY
Mile #3 - "Flow"
Maximize efficiency, minimize wasteful handling.
“Time is money”
- HOW DOES PRODUCTION MOVE? PROGRESSIVELY?
- KEEP THE PRODUCT FLOWING
- STREAMLINE
- IN PROCESS KANBAN
- REWORK LOOP
- FINISHED GOODS
Mile #4 - "Product Manipulation"
How we handle and manipulate is our focus. Create an ergonomic workplace environment.
“A stitch in time saves nine”
- FIXTURING MANIPULATION
- ROTATION
- PACKAGE SIZE/WEIGHT/ACCESS
- LIFT OFF FINISHED PRODUCT
- MINIMIZE NON-VALUE/WASTEFUL HANDLING
Mile #5 - "Parts Presentation"
Maximize efficiency, minimize look and reach.
We don’t need or want to fight the process.
“Lost time is never found”
- KITS AT STATIONS
- PRESENTED ON ASSEMBLY FIXTURE
- 2 BIN KANBAN
- BULK MATERIAL PRESENTATION
- INVENTORY TURNS/PULLS
- HOW MANY
- WASTE/TRASH HANDLING
- EMPTY CONTAINER HANDLING
Mile #6 - "Tools/Utilities"
We’re setting up the work position with what is needed, where it’s need and nothing more.
“Everything in place and a place for everything”
- PRESENTATION/SHADOWBOARD
- ONLY WHAT IS REQUIRED/ESSENTIAL
- UTILITIES, AIR/POWER/VACUUM/EXHUAST
- OFFLINE EQUIPMENT POSITIONS
- GAUGES
- DISPENSERS
- COMMUNICATIONS/DATA
- COMPUTERS
- LIGHTING
- ANDON LIGHT
- SCANNERS
- TEST EQUIPMENT
- PRINTERS
- CABLES
Mile #7 - "Execute"
The beginning of the beginning. We run, record results, refine, rerun, and repeat it all. Always looking for incremental gain.
“Diligence is the seed of good luck”. “If we don’t quantify, we can’t improve.”
- PILOT RUN
- REVIEW PROCESS
- PRODUCTION RUN
- EVALUATE RESULTS
- COMMUNICATE WITH TEAM
- IMPROVE
- IDENTIFY OPPORTUNITES
- KAIZEN TO ENHANCE PRODUCTION
