Assembly in Action: Fixture Redesign Cuts Cycle Time in Half
It all began in early 2001, when Honda invited Humantech (Ann Arbor, MI) to assist its ergonomics team with ergonomics improvements in the plant. Later that year, Honda of America associates identified the fender-finishing operation in the weld department as a candidate for redesign. The operation involved reaching forward as far as 28 inches, awkward upper body postures, and 24 lifts of a 12-pound part in an average operating cycle. The average cycle time was 30 minutes.
Associates used ergonomic principles to design the new freestanding fixture in two iterations. The new fender positioner is height-adjustable and requires only two liftsto load and unload the part. It is simple to operate, allowing users to maneuver and lock the partwithout liftinginto different positions. Forward reach was reduced to 15 inches, and awkward postures have been eliminated. Associates who once avoided the operation have enthusiastically accepted the new concept.