Lean Assembly : The Nuts and Bolts of Making Assembly Operations Flow book cover
1st Edition

Lean Assembly
The Nuts and Bolts of Making Assembly Operations Flow

ISBN 9781563272639
Published October 2, 2002 by Productivity Press
296 Pages

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Book Description

With examples drawn from aerospace, electronics, household appliance, personal products, and automotive industries, Lean Assembly covers the engineering of assembly operations through:

  • Characterizing the demand in terms of volume by product and product family, component consumption, seasonal variability and life cycle.
  • Matching the physical structure of the shop floor to the demand with the goal of approaching takt-driven production as closely as possible.
  • Working out the details of assembly tasks station by station, including station sizing, tooling, fixturing, operator instructions, part presentation, conveyance between stations, and the geometry of assembly lines as a whole.
  • Incorporating mistake-proofing, successive inspection, and test operations for quality assurance.

    Lean Assembly differs from most other books on lean manufacturing in that it focuses on technical content as a driver for implementation methods. The emphasis is on exactly what should be done. This book should be the "dog-eared" and "penciled-in" resource on every assembly engineer's desk.

Table of Contents

PART A: Analysis Techniques

Chapter 1: Key issues of assembly operations
Chapter 2: Product quantity analysis
Chapter 3: Trend and seasonality analysis
Chapter 4: Takt time and capacity

PART B: Assembly Concepts

Chapter 5: Visualizing the assembly process
Chapter 6: The concept of the assembly line
Chapter 7: Collecting assembly time data
Chapter 8: Line balancing

PART C: Detailed Design

Chapter 9: Assembly station sizing
Chapter 10: Detailed design of assembly stations
Chapter 11: Part presentation
Chapter 12: Conveyance between stations
Chapter 13: Assembly cells
Chapter 14: Overall shape of assembly lines

PART D: Assembly Quality

Chapter 15: Preventing picking errors
Chapter 16: Inspection, test, and rework operations


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"Designing and implementing lean production systems presents a never-ending host of curious puzzles. Experienced practitioners as well as novices will find Michel Baudin's Lean Assembly full of creative solutions."

Tom Berghan, Lean Specialist, Korry Electronics 06/01/04

"Lean Assembly will be a vital resource to those at the forefront of Lean implementation. It shows the reader how to properly analyze and design assembly systems, while working out all the details such as incorporating mistake-proofing concepts. Lean Assembly will find itself on the desk of the Lean Implementer rather than on a bookshelf collecting dust."

Dale Bayley, Lean Champion, Racor Division, Parker Hannifin 06/01/04