Application of the A3 Methodology for the Improvement of an Assembly Line

摘要

In an increasingly and globally competitive industry like the automotive sector, the continuous improvement of processes assumes a key role in the enhancement of effectiveness and efficiency. In line with this philosophy, the study undertaken of the work method and its inherent activities has pointed to time measurement as agembasupport tool of great potential in the optimization of the production process and the elimination ofmudas. The present case study relates to the improvement of productivity of an assembly line dedicated to the manufacture of brake cables for the automotive industry. The application of the A3 methodology to this improvement project aims to monitor the evolution of key indicators as productivity per hour and the Overall Equipment Effectiveness (OEE) of the assembly line, to define the different improvement actions to be executed, and to achieve the defined target, and to validate the results of its implementation. The measurement of the different activities of the assembly line allowed to identify the major wastes (of material movements, operator movements, among others.) and to identify the most critical workstations that contribute for the unbalancing of the assembly line. The solutions implemented allowed to increase the productivity by 49% and, as a consequence, reduce the cycle time in 33%. The rearrangement and improvement of operations allowed also to increase the efficiency of the assembly line balancing in 11%. As the A3 methodology assumed a key role for this project, allowing the monitoring of the effectiveness of the different improvement actions implemented, it was standardized so that it could be applied to other improvement projects.