CONTAGEM, Brazil--GE Transportation’s plant here unveiled this week a new approach to manufacturing locomotives with a mixed-model moving assembly line. Unlike traditional stationary production lines, the mixed-model moving line is designed to assemble different locomotive configurations as the units slowly move down the track. The assembly line cuts lead time by approximately 20 percent, reduces inventory by $1.75 million and creates 1,256 square meters of space savings within the factory.

Mixed-model assembly lines present numerous opportunities for manufacturers, but they also create headaches for engineers. Lean manufacturing guru, Drew Locher, offers some tips.

Manufacturers today are producing a wider range of products than ever. Life cycles are shrinking and demand for customization is increasing. As a result, assembly lines must be as flexible as possible without compromising efficiency. That’s why companies producing everything from pumps to pistols and caskets to chainsaws depend on mixed-model assembly.

Simulation software can help manufacturing engineers balance conflicting objectives on a mixed-model assembly line.