This project was executed in two phases: optimization of a single assembly lab, followed by expansion of the methodology to the full manufacturing plant.

 

The results shown below reflect the single-lab optimization; however, the same approach was later applied across all assembly operations.

The initial phase focused on a dedicated assembly lab designed to build and test a single product. While part design and core assembly steps could not be modified, we had flexibility to redesign tooling, reconfigure workstations, and reassign labor.

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Although new tooling and workstation changes improved operator ergonomics, the most impactful insights came from a detailed time study and workflow (spaghetti) diagram. This analysis revealed significant inefficiencies driven by task sequencing, operator idle time, and excessive part handling.

By reordering operations based on setup time, run time, and functional dependencies, we transformed the assembly cell to significantly improve throughput and flow.