1st Edition

Lean Assembly The Nuts and Bolts of Making Assembly Operations Flow

By Michel Baudin Copyright 2002
    292 Pages
    by Productivity Press

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    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.

    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


    "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