LEAN MANUFACTURING METHODOLOGY FOR IMPROVING PRODUCTION FLOWS ON AN ASSEMBLY LINE

Purpose – The article presents another stage of development of the methodology for improving production flows on an assembly line in the automotive industry.

Approach – The Lean Manufacturing methodology was developed to present in a logical chaining way the methods specific to this concept of production management, and as to allow efficient analysis and continuous increase of the performance of an assembly line. This chaining requires that, according to the results of each method application, specific paths/ methods will be followed/ applied.

Findings – This methodology was experimented and validated in the laboratory which integrates an experimental demonstrator (an assembly line of an experimental product), software (to analyse, improve or optimize different layouts of the workstations or line production and production flows) and specific concepts (learning, experimenting and research platforms) of the Lean Learning Factory. Along with the “Lean cubes” platforms, for each Lean method (5S, VSM, DOJO, Poka-Yoke etc.), flowcharts and tables specific to their application were made.

Research limitations/implications – The developed methodology allowed the increase, during the project/ research, of the TRL level (technological training level) of the experimental demonstrator from 2 to 4. The platforms specific to Lean methods can be used for other production systems, being able to be used successfully in any Lean learning factory, but the experimental demonstrator is intended only for assembly lines.

Practical implications – The lean manufacturing methodology presented in this paper can be used successfully in the "Lean learning factory" type laboratory for the education and training of students and employees of companies in the automotive industry.

Originality/value – The study is part of a research project of the authors, which has as aim the development of a methodology of improvement of production flows in the automotive industry, by integrating modern techniques and instruments of production management.