WORKSHOP #2: Lean Manufacturing and Manual Assembly
Manual assembly remains the most popular way to put together a product. Indeed, according to ASSEMBLY magazine’s annual Capital Equipment Spending Survey, 87 percent of factories employ at least some manual operations to assemble their products. That figure has remained constant for the past 24 years, and it’s not all that surprising. After all, people are the most flexible assembly machines—just ask Tesla’s CEO, Elon Musk!
Designing, equipping and managing a largely manual assembly process requires a different skillset than a highly automated one. In this workshop, you’ll learn tips and tricks for creating efficient line layouts; improving your operation; error-proofing your process; and preventing work-related injuries. If your operation is mostly manual, you won’t want to miss this workshop!
1:00 – 1:35 PM ET
Lean Layout Do’s and Don’ts
Optimizing flow and minimizing waste are two of the basic elements of lean manufacturing. Those concepts also play a critical role in laying out assembly lines. The way in which workstations and tools are arranged can affect ergonomics, productivity and throughput. Lean lines should accommodate increasing product variety without compromising quality or introducing waste into the process. Unfortunately, many manufacturers struggle with issues related to line layout. This presentation will provide advice on designing assembly lines for maximum efficiency.
Jeffrey Miller, PE, Managing Principal, Productivity Engineering Services LLC
1:35 – 2:10 PM ET
The ABCs of A3 Reports
A3 reports are a simple way of getting a problem, an analysis, or a corrective action plan written down on a single sheet of large paper, often with the use of graphics. A powerful lean management tool, these reports help to structure thinking, tell a concise PDCA (Plan-Do-Check-Act) story, and generate discussion with management. In this presentation, you’ll learn how to create an A3 report from Art Smalley, lean guru and co-author of the book, Understanding A3 Thinking (Productivity Press).
Art Smalley, Art of Lean Inc.
2:10 – 2:45 PM ET
Best Practices for Ergonomics on the Assembly Line
Manual assembly processes can be improved if engineers consider ergonomic guidelines that address job-related stressors, such as force, position, repetition and vibration. Poor ergonomic design directly affects productivity, efficiency and quality from an assembly line. In this presentation, you’ll learn how to address work heights, reach standards and other ergonomic issues when designing assembly lines and workstations. The presentation will also cover best practices for preventing the spread of COVID-19.
Timothy A. Pottorff, CIE, ARM, Principal, QP3 ErgoSystems LLC
2:45 - 2:55 PM ET
2:55 – 3:30 PM ET
Lean Manufacturing and Manual Assembly - IIoT With Manual Assembly
Nobody’s perfect. Even the best trained, most experienced assemblers can make mistakes on the line, especially in high-mix production environments. Fortunately, a variety of software products are available to help prevent assembly errors. However, today’s state-of-the-art tools do more than just guide operators. Digital work instructions help drive productivity, improve efficiency, simplify connectivity and enhance Industry 4.0 initiatives. In this presentation, you will learn:
- Best practices in digitizing a standard process.
- How to reduce the cost of error proofing.
- Selecting and implementing hardware.
- Increase wealth for all your stakeholders.
- How to integrate software and ERP systems.
Ben Marsh, President and CEO, Scout Systems Inc.
3:30 - 4:00 PM ET
Q&A with Workshop Panelists
MODERATOR: Austin Weber, Senior Editor, Assembly Magazine