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On a broad level, manufacturing more efficiently can help cut costs, improve throughput and reduce environmental impact. All of these general benefits lead to additional benefits down the road, from increased sales and quality to improved company image
There’s no substitute for hands-on, real-world training. Take stock in your employees by training them on multiple processes; that way, they can help one another troubleshoot, act as substitutes, and provide relief during repetitive tasks. Furthermore, if everyone on the factory floor has a good grasp of the entire process from start to finish, they’ll have a better understanding of their roles within that process
Assign a point value, or better yet, a dollar value, to every aspect of your manufacturing process. Material costs are obvious, but take into account man-hours, equipment wear and tear, and planned obsolescence to further quantify production. By assigning numbers to every aspect of manufacturing, you’ll make it a lot easier to see which areas need immediate attention
Organization is key to an efficient workspace. Take a look around your factory floor. Are hand tools easy to find? Are waste products piling up in the corner? All tools, parts, materials and instructions should have a home, and every employee should know where that home is
Start by making a checklist, and placing it in each workspace. Then, make sure that every employee who does a job in that workspace follows the checklist. This simple act can reduce downtime and improve overall product quality
Taken directly from the Lean Manufacturing playbook, cellular manufacturing is a method of improving efficiency by grouping similar processes. The methodology involves dividing workspaces into cells, and assigning each cell a standardized set of tasks. The machines (and employees) in each cell might be capable of carrying out a wide variety of jobs, but allowing them to focus on a single job decreases downtime for tasks like re-calibration and tooling installation, while improving consistency and quality
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The assembly line is one of the greatest inventions of the 20th century. Often mentioned among the first disruptive practices, it shook the world so profoundly that manufacturers who failed to adapt to it closed their business.
The assembly line was more than just an invention that sped up manufacturing processes – it was an idea, a methodology, which strived to increase efficiency and output. Almost every industry quickly adopted and adapted it to better suit their needs and it continued to evolve and thrive up to this day
Today, the most widely used term among manufacturers is lean manufacturing – an assembly line that runs optimally, without delays or issues, with minimum waste and maximum productivity. These properties are the goal of every business today, not only those related to manufacturing
The first part of this guide follows the assembly line from its humble beginning and earliest prototypes, Henry Ford’s major breakthrough, to Toyota’s contribution to the assembly line and lean manufacturing. The guide then transitions to today’s modern lines, their organizational aspect, new technologies, integration of AI and machine learning, and other disruptive methods taking the world by storm.
When the term “car production” is mentioned in conversation, most people immediately think of Henry Ford and his revolutionary assembly lines, but the truth is much more complex. For starters, the assembly line was patented not by Ford, but another auto industry giant, one who is credited with creating the modern auto industry as we know it yet isn’t a household name
In this chapter, we will list how the car production lines as we know it came to be and how the constant pursuit of efficiency and better quality products across industries led to them. This chapter will deal with their history, and the importance of the division of labor, interchangeable parts and similar concepts from other industries all played a major role in their evolution
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