CASE STUDY: TIME-BASED BENEFITS OF AGILE ASSEMBLY LINES COMPARED TO ASSEMBLY IN A GROUP OF CELLS

This paper presents a case study comparing the assembly of hoists grouped by function and assembly organised into short visually controlled agile assembly lines. The purpose of the study is to analyse the benefits and disadvantages of the three systems. The study is focused on differences in quantitative factors such as production hours and assembly lead time. The case assembly system produces 2000 units annually. Products are assembled in four main stages and in some subassembly cells. There are 4 different types of product in production, and every type has some variation, but the main process flow is the same. During the study the assembly system was changed from groups to flow lines. The system output was registered before the change, during the change, and after the change. The actual lead times of the products are also registered at the same time. There are several potential benefits in assembly lines compared to cells. The simulation shows an 11% decrease in direct assembly hours. The time is in line with experience with the case system. The lead time decreased from 2.5 days to 1 day in the simulation; this was also in line with the results with the case system.