Project Overview
Lean On Us successfully delivered a comprehensive turnkey solution for the design, manufacturing, installation, and commissioning of an advanced auto parts assembly line for a leading global supplier of drivetrain, mobility, braking, and electric powertrain solutions. Our expertise in Lean methodologies, industrial automation, and process optimization enabled us to achieve superior productivity, efficiency, and cost-effectiveness.
Client Background
The client is a global leader in the commercial vehicle and industrial markets with over 110 years of innovation, providing high-performance solutions for commercial trucks, trailers, off-highway, defense, specialty, and aftermarket customers worldwide.
Project Challenges
- Turnkey Assembly Line Execution: Design, manufacture, test, install, and commission an advanced auto parts assembly line, ensuring seamless integration of components while optimizing production efficiency and maintaining compliance with industry standards.
- Optimized Product Line Design: Develop a holistic, resource-efficient assembly line solution by balancing Design Engineering, Industrial Engineering, and Production Engineering principles.
- Cost and Time Optimization: Ensure the project meets budget constraints while being delivered within the agreed timeline.
Project Approach
- Concept Development & Process Design
Our first step was extensive research and analysis, collaborating with process experts to understand the suspension assembly domain. We engaged a cross-functional team of engineers, designers, and subject matter experts to develop and refine innovative concepts for the assembly line.
We mapped out the entire assembly process, considering critical factors such as:
- Material Selection: Ensuring the best quality and cost-effective raw materials.
- Manufacturing Techniques: Implementing cutting-edge automation and lean principles.
- Quality Control: Integrating error-proofing mechanisms (Poka-Yoke) and Six Sigma methodologies.
- Resource Optimization: Leveraging Lean principles and SMED (Single-Minute Exchange of Dies) techniques for operational efficiency.
- Assembly Line Design: Fixtures & Machines
With a solid concept in place, we proceeded with detailed engineering, designing:
- Ergonomically Designed Workstations: To enhance operator comfort and reduce fatigue, we conducted human-centric studies, prototype testing, and user feedback analysis. The resulting workstation designs improved productivity while ensuring workplace safety.
- Lean Line Layout: Designed the shop floor layout to minimize waste, streamline movement, and maximize efficiency.
- Automation & Fixtures: Developed custom fixtures and integrated automated solutions for precision and repeatability.
- Poka-Yoke Implementation: Identified critical areas prone to human error and integrated error-proofing mechanisms across all key processes.
- Manufacturing & Assembly Line Commissioning
After finalizing the design, we moved into full-scale manufacturing and commissioning:
- Manufacturing of Assembly Line Components: Produced and tested all critical components, ensuring high durability and efficiency.
- Pre-Assembly & Testing: Conducted rigorous quality checks and pre-assembly validation to mitigate any potential issues before final deployment.
- Installation & Commissioning: Executed seamless integration of machines, fixtures, and automation systems at the client’s facility.
- Standard Operating Procedures (SOPs): Documented and implemented SOPs for all critical processes to standardize operations and ensure quality consistency.
- Training & Handholding: Provided comprehensive training to the client’s workforce on operational best practices, Lean methodologies, and Poka-Yoke implementation.
Key Achievements
- Cost Leadership: Delivered the project at 60% of the nearest competitor’s pricing.
- Accelerated Delivery: Completed and handed over the project 4 weeks ahead of the quoted lead time.
- Enhanced Productivity: Implemented a lean assembly line layout, reducing waste and maximizing efficiency.
- Robust Quality Control: Successfully integrated SOPs and Poka-Yoke mechanisms across all critical processes, minimizing defects and ensuring long-term reliability.
Conclusion
Through meticulous planning, innovative design, and disciplined execution, Lean On Us successfully delivered a high-performance auto parts assembly line. Our expertise in turnkey solutions, Lean methodologies, and industrial automation helped our client achieve substantial cost savings, improved productivity, and enhanced quality standards.