Automotive OEMs and Tier 1s are increasingly separating specific assembly processes from the main production line as part of their lean manufacturing model.
SEATTLE—Lean manufacturing has enabled Boeing to make dramatic improvements in efficiency. Assembly time for the 777 jetliner has been reduced from 71 days to 37. Assembly time for the 737 jetliner has been cut from 20 days to 11.
Alabama is home to state-of-the-art auto plants operated by Daimler, Honda, Hyundai and Toyota. It’s also home to a state-of-the-art assembly line that builds toy cars out of Lego blocks: Tiger Motors.
The widespread availability of modular profile systems has made it easy for engineers to get in touch with their creative side. They enable assemblers to bolt together framing components to tailor workstations and machines to specific processes or floor space requirements.
Tim Hutzel will never forget the first time, back in 1995, that he walked the shop floor at Hamilton Caster & Manufacturing Co., a maker of industrial wheels, casters, carts and trailers in Hamilton, OH. Hutzel had just left his job as director of lean transformation at GE Aviation to strike out on his own as a consultant and lean guru. Hamilton Caster was his first customer.