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“As model mix increases, so does the proliferation of parts and subassemblies that need to be presented line-side,” notes Miller. Unless the line is properly balanced, you’ll end up with overstaffing or regularly scheduling overtime to meet customer demand. “Since the work content for each of the models will be different, this can lead to uneven flow along the line. “Producing more than one model simultaneously on an assembly line presents a number of challenges,” says Jeffrey Miller, P.E., managing principal at Productivity Engineering Services LLC. Many engineers are reluctant to modify their assembly lines, because changing line layout tends to be quite disruptive. One reason is that products are changing more frequently today. Unfortunately, many manufacturers struggle with issues related to line layout.
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Whether it’s a high-volume, low-mix environment or a low-volume, high-mix line, flexibility is critical.
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Lean lines should accommodate increasing product variety without compromising quality or introducing waste into the process. The way in which workstations and tools are arranged can affect ergonomics, productivity and throughput. Those concepts also play a critical role in laying out assembly lines. Optimizing flow and minimizing waste are two of the basic elements of lean manufacturing.