Articles about how to eliminate waste and continuously improve your assembly operation. https://www.assemblymag.com/rss/2635-lean-manufacturing-assembly en-us moorej@bnpmedia.com (JJ Moore) NEW YORK — AI-enabled digital twins are moving deeper into high-volume manufacturing as producers look for faster ways to reduce waste, improve quality and adjust production processes in real time. NEW YORK — AI-enabled digital twins are moving deeper into high-volume manufacturing as producers look for faster ways to reduce waste, improve quality and adjust production processes in real time.

]]> http://www.assemblymag.com/articles/100150 Fri, 19 Jun 2026 07:00:00 -0400 https://www.assemblymag.com/articles/100150-accenture-ai-digital-twins-help-cut-waste-improve-throughput A turnkey engineered system helps manufacturers safely and efficiently remove wood pallet waste from the production floor, then convert wood and metal materials into sustainable secondary uses. A turnkey engineered system helps manufacturers safely and efficiently remove wood pallet waste from the production floor, then convert wood and metal materials into sustainable secondary uses.

]]> http://www.assemblymag.com/articles/100127 Mon, 08 Jun 2026 00:00:00 -0400 https://www.assemblymag.com/articles/100127-wood-pallet-trash-solution-sustainable-outcome For manufacturers seeking to improve operational performance, understanding how waste appears on the shop floor — and how to remove it — is often the first step toward a more efficient production environment. For manufacturers seeking to improve operational performance, understanding how waste appears on the shop floor — and how to remove it — is often the first step toward a more efficient production environment.

]]> http://www.assemblymag.com/articles/99933 Wed, 01 Apr 2026 09:00:00 -0400 https://www.assemblymag.com/articles/99933-eliminating-waste-on-the-shop-floor-applying-lean-principles-to-improve-manufacturing-efficiency sprovierij@bnpmedia.com (John Sprovieri) The MEP is a program administered by the National Institute of Standards and Technology. The program’s mission is to strengthen and empower small and medium-sized U.S. manufacturers. The MEP is a program administered by the National Institute of Standards and Technology. The program’s mission is to strengthen and empower small and medium-sized U.S. manufacturers.

]]> http://www.assemblymag.com/articles/99939 Wed, 25 Mar 2026 11:00:00 -0400 https://www.assemblymag.com/articles/99939-training-aids-management-at-harness-assembler htang2@emich.edu (Herman Tang Ph.D.) For engineers and operations managers seeking to improve production performance, selecting the right throughput metrics is critical. This article outlines practical measurement approaches to help monitor, diagnose and improve your manufacturing operations. For engineers and operations managers seeking to improve production performance, selecting the right throughput metrics is critical. This article outlines practical measurement approaches to help monitor, diagnose and improve your manufacturing operations.

]]> http://www.assemblymag.com/articles/99938 Tue, 24 Mar 2026 10:00:00 -0400 https://www.assemblymag.com/articles/99938-measuring-what-matters-an-engineers-guide-to-manufacturing-kpis Power distribution shouldn’t lock a facility into one layout. Here’s how engineers are designing leaner, code-compliant power systems using single-phase and three-phase busway configurations. Power distribution shouldn’t lock a facility into one layout. Here’s how engineers are designing leaner, code-compliant power systems using single-phase and three-phase busway configurations.

]]> http://www.assemblymag.com/articles/99835 Sun, 01 Mar 2026 09:00:00 -0500 https://www.assemblymag.com/articles/99835-choosing-busway-the-smarter-way sprovierij@bnpmedia.com (John Sprovieri) The Augmentir connected worker platform is designed to help manufacturing and service teams improve operations, close skills gaps, capture tribal knowledge, and drive continuous improvement efforts. The Augmentir connected worker platform is designed to help manufacturing and service teams improve operations, close skills gaps, capture tribal knowledge, and drive continuous improvement efforts.

]]> http://www.assemblymag.com/articles/99861 Tue, 24 Feb 2026 09:00:00 -0500 https://www.assemblymag.com/articles/99861-connected-worker-software-improves-training By optimizing workflow and minimizing strain, ergonomic adjustments can increase efficiency and help employees perform tasks more effectively. By optimizing workflow and minimizing strain, ergonomic adjustments can increase efficiency and help employees perform tasks more effectively.

]]> http://www.assemblymag.com/articles/99818 Wed, 04 Feb 2026 09:00:00 -0500 https://www.assemblymag.com/articles/99818-can-ergonomic-improvements-increase-productivity Starline's director of commercial and industrial sales, Adrian Sanchez, explains how outdated power systems can quietly undermine innovation, increase downtime, and slow time-to-market. Starline's director of commercial and industrial sales, Adrian Sanchez, explains how outdated power systems can quietly undermine innovation, increase downtime, and slow time-to-market.

]]> http://www.assemblymag.com/articles/99757 Fri, 09 Jan 2026 15:00:00 -0500 https://www.assemblymag.com/articles/99757-power-distribution-strategy-is-important-for-smart-manufacturing sprovierij@bnpmedia.com (John Sprovieri) Modular, adjustable, mobile workstations that adapt to employees’ natural movements support continuous improvement while maintaining safety and efficiency. Modular, adjustable, mobile workstations that adapt to employees’ natural movements support continuous improvement while maintaining safety and efficiency.

]]> http://www.assemblymag.com/articles/99726 Tue, 30 Dec 2025 13:00:00 -0500 https://www.assemblymag.com/articles/99726-custom-workstations-improve-ergonomics ergonomic workstation Studies demonstrate that ergonomic work environments increase productivity by 25 percent and lower absenteeism by 75 percent. ergonomic workstation Engineers should consider who will be using the workstation and how. Will the work be done sitting or standing? Will different people use the workstation over the course of a workday? Automated material handling system replaces forklifts and manual transport. Automated material handling system replaces forklifts and manual transport.

]]> http://www.assemblymag.com/articles/99667 Thu, 20 Nov 2025 09:00:00 -0500 https://www.assemblymag.com/articles/99667-automation-boosts-efficiency-at-drive-manufacturer Jay Tavakolian, operations program director at Intricon, offers insight into the precision, scalability, and innovation required to accelerate production of micro medical devices while minimizing risk throughout the development cycle. Jay Tavakolian, operations program director at Intricon, offers insight into the precision, scalability, and innovation required to accelerate production of micro medical devices while minimizing risk throughout the development cycle.

]]> http://www.assemblymag.com/articles/99634 Fri, 31 Oct 2025 16:00:00 -0400 https://www.assemblymag.com/articles/99634-tips-for-assembling-micro-medical-devices Tribal knowledge, such as a unique method of soldering a specific component, is often lost when an assembly line is transferred to another location. Tribal knowledge, such as a unique method of soldering a specific component, is often lost when an assembly line is transferred to another location.

]]> http://www.assemblymag.com/articles/99597 Fri, 10 Oct 2025 09:00:00 -0400 https://www.assemblymag.com/articles/99597-when-documented-work-instructions-dont-match-reality soldering a component onto a circuit board Tribal knowledge, such as a unique method of soldering a specific component, is often lost when an assembly line is transferred to another location.  electronics assembly Often, documented work instructions don’t match the way the job is actually being done on the floor. Manufacturers can use AI and analytics to base production on real-time consumer demand and feedback. Manufacturers can use AI and analytics to base production on real-time consumer demand and feedback.

]]> http://www.assemblymag.com/articles/99593 Thu, 02 Oct 2025 14:30:00 -0400 https://www.assemblymag.com/articles/99593-are-you-ready-for-consumer-driven-manufacturing webera@bnpmedia.com (Austin Weber) MUNICH—BMW plants in Landshut and Wackersdorf, Germany, creates instrument panels just-in-time to minimize overproduction, excess inventory and waste. MUNICH—BMW plants in Landshut and Wackersdorf, Germany, creates instrument panels just-in-time to minimize overproduction, excess inventory and waste.

]]> http://www.assemblymag.com/articles/99586 Thu, 02 Oct 2025 09:00:00 -0400 https://www.assemblymag.com/articles/99586-bmw-plants-honored-for-lean-manufacturing sprovierij@bnpmedia.com (John Sprovieri) Item America’s new Ergologistics line of workbenches takes in the entire assembly process, from material supply and transport to production at the workbench. Item America’s new Ergologistics line of workbenches takes in the entire assembly process, from material supply and transport to production at the workbench.

]]> http://www.assemblymag.com/articles/99500 Wed, 20 Aug 2025 09:00:00 -0400 https://www.assemblymag.com/articles/99500-workstations-balance-needs-of-logistics-and-ergonomics Item America's Ergologistics line of workbenches Resolving the conflict between logistics efficiency and ergonomics is the concept behind the Ergologistics line of workbenches. color-coded parts containers Color coding makes it easy for assemblers to pick the correct parts.  Worksmart Systems' Fleximate® System flows assembly, test and related tasks and eliminates wasteful handling and labor. Worksmart Systems' Fleximate® System flows assembly, test and related tasks and eliminates wasteful handling and labor.

]]> http://www.assemblymag.com/articles/99465 Thu, 31 Jul 2025 11:00:00 -0400 https://www.assemblymag.com/articles/99465-worksmart-systems-inc LEAN Manufacturing Products LLC leads the industry with innovative, tailored material handling and storage solutions designed to elevate their customers manufacturing efficiency. LEAN Manufacturing Products LLC leads the industry with innovative, tailored material handling and storage solutions designed to elevate their customers manufacturing efficiency. 

]]> http://www.assemblymag.com/articles/99410 Thu, 24 Jul 2025 10:00:00 -0400 https://www.assemblymag.com/articles/99410-lean-manufacturing-products Kaizen is a key tool for creating a culture of continuous improvement. Kaizen is a key tool for creating a culture of continuous improvement. 

]]> http://www.assemblymag.com/articles/99349 Thu, 26 Jun 2025 09:00:00 -0400 https://www.assemblymag.com/articles/99349-kaizen-unlocks-hidden-value-in-manufacturing sprovierij@bnpmedia.com (John Sprovieri) Flexibility on assembly lines is more important than ever. A product that was run one week may not get produced at all the next. Assembly cells must be rearranged; part supplies must be repositioned; and it all must be done quickly and efficiently. Flexibility on assembly lines is more important than ever. A product that was run one week may not get produced at all the next. Assembly cells must be rearranged; part supplies must be repositioned; and it all must be done quickly and efficiently.

]]> http://www.assemblymag.com/articles/99269 Mon, 19 May 2025 12:30:00 -0400 https://www.assemblymag.com/articles/99269-modular-components-lend-flexibility-to-assembly-lines Manufacturing leaders struggle with the choice between embracing change or risking stagnation, often delaying the adoption of lean manufacturing. Despite its benefits, resistance stems from entrenched habits and misunderstandings of its full potential. Manufacturing leaders struggle with the choice between embracing change or risking stagnation, often delaying the adoption of lean manufacturing. Despite its benefits, resistance stems from entrenched habits and misunderstandings of its full potential.

]]> http://www.assemblymag.com/articles/99171 Mon, 07 Apr 2025 16:00:00 -0400 https://www.assemblymag.com/articles/99171-balancing-innovation-and-stability-with-lean webera@bnpmedia.com (Austin Weber) Artificial intelligence technology energizes manual assembly lines. Artificial intelligence technology energizes manual assembly lines.

]]> http://www.assemblymag.com/articles/99042 Wed, 05 Feb 2025 10:30:00 -0500 https://www.assemblymag.com/articles/99042-using-ai-to-improve-productivity-and-quality sprovierij@bnpmedia.com (John Sprovieri) The presses stamp out 17 million parts annually with an accuracy of ±0.1 millimeter. The presses stamp out 17 million parts annually with an accuracy of ±0.1 millimeter.

]]> http://www.assemblymag.com/articles/98921 Wed, 27 Nov 2024 09:00:00 -0500 https://www.assemblymag.com/articles/98921-automotive-stamping-line-is-fast-and-flexible sprovierij@bnpmedia.com (John Sprovieri) Some 23 hardware and software suppliers will demonstrate the latest technology at The ASSEMBLY Show. Some 23 hardware and software suppliers will demonstrate the latest technology at The ASSEMBLY Show.

]]> http://www.assemblymag.com/articles/98805 Wed, 02 Oct 2024 12:00:00 -0400 https://www.assemblymag.com/articles/98805-new-software-promises-to-increase-quality-flexibility-and-resilience PFMEA ensures that the prototype parts from the assembly line meet quality expectations, thereby maturing the manufacturing processes. PFMEA ensures that the prototype parts from the assembly line meet quality expectations, thereby maturing the manufacturing processes.

]]> http://www.assemblymag.com/articles/98720 Fri, 30 Aug 2024 09:00:00 -0400 https://www.assemblymag.com/articles/98720-to-ensure-quality-connect-pfmea-control-plans-and-testing quality management By integrating PFMEA, the control plan and testing, manufacturers can create a robust quality management system that ensures process reliability, reduces failure risk, and delivers consistent product quality. Photo courtesy Webasto Group evaluating manufacturing processes PFMEA is a systematic method for evaluating manufacturing processes. Photo courtesy ZF evaluating manufacturing processes During PFMEA, engineers rate each failure mode on a scale from 1 to 10 according to its severity, likelihood and detectability.  Photo courtesy Voelker instrument cluster The author once worked on a project to develop an instrument cluster for a new vehicle. A PFMEA identified a potential failure mode related to the adhesive used to assemble the cluster. Process validation testing confirmed that the problem could, indeed, occur. Photo courtesy Jon Quigley Multimedia Editor and Host Jennifer Pierce shares highlights from the ASSEMBLY Audible podcast. Multimedia Editor and Host Jennifer Pierce shares highlights from the ASSEMBLY Audible podcast.

]]> http://www.assemblymag.com/articles/98535 Tue, 14 May 2024 00:00:00 -0400 https://www.assemblymag.com/articles/98535-safety-excellence-assembly-plant-management-and-the-worlds-tiniest-computers To meet safe launch for an automotive component, a Michigan company had to manufacture 4,000 assemblies with zero defects. MES software helped the company do it. To meet safe launch for an automotive component, a Michigan company had to manufacture 4,000 assemblies with zero defects. MES software helped the company do it.

]]> http://www.assemblymag.com/articles/98494 Tue, 23 Apr 2024 15:22:00 -0400 https://www.assemblymag.com/articles/98494-mes-software-improves-assembly Pico and Pollington manufacturing 3 Pico and Pollington manufacturing 4 Pico and Pollington manufacturing 2 A massive order inspires a German company to redesign its assembly process. A massive order inspires a German company to redesign its assembly process.

]]> http://www.assemblymag.com/articles/98447 Mon, 08 Apr 2024 15:00:00 -0400 https://www.assemblymag.com/articles/98447-how-to-boost-production-by-six-fold A new report from Bain & Company outlines the potential for productivity gains in the machinery industry. A new report from Bain & Company outlines the potential for productivity gains in the machinery industry.

]]> http://www.assemblymag.com/articles/98444 Thu, 04 Apr 2024 18:27:09 -0400 https://www.assemblymag.com/articles/98444-report-machinery-industry-could-boost-productivity-by-50-through-ai-and-digital-transformation Multimedia Editor and Host Jennifer Pierce shares highlights from the ASSEMBLY Audible podcast. Multimedia Editor and Host Jennifer Pierce shares highlights from the ASSEMBLY Audible podcast.

]]> http://www.assemblymag.com/articles/98438 Thu, 04 Apr 2024 09:00:00 -0400 https://www.assemblymag.com/articles/98438-kaizen-automation-and-the-automotive-industry-in-2024