| Figures | p. xi |
| Tables | p. xvii |
| A guided tour | p. 1 |
| Analysis techniques | p. 3 |
| Key issues of assembly operations | p. 5 |
| What is assembly? | p. 6 |
| Scope of this book | p. 6 |
| Assembly = assembly and test | p. 6 |
| Factors in assembly performance | p. 8 |
| Part supply | p. 8 |
| Assembly work design | p. 9 |
| Examples | p. 10 |
| Waste in assembly work | p. 11 |
| Recognizing waste in assembly work | p. 11 |
| Eliminating assembly waste | p. 13 |
| Product quantity analysis | p. 15 |
| Purpose | p. 16 |
| The concept of P-Q analysis | p. 17 |
| Difference with Group Technology | p. 18 |
| Bill of materials analysis for mixed-flow lines | p. 20 |
| Order profiling for custom assembly | p. 25 |
| Trend and seasonality analysis | p. 27 |
| Purpose | p. 28 |
| Responding to demand variability over time | p. 29 |
| Data aggregation | p. 30 |
| Making the sales data talk | p. 32 |
| Demand variability upstream in the supply chain | p. 37 |
| Conclusions | p. 39 |
| Takt time and capacity | p. 41 |
| What is the takt time? | p. 41 |
| Definition of the term | p. 42 |
| Design takt time and operation takt time | p. 44 |
| Common mistakes about takt time | p. 45 |
| Why takt time matters | p. 46 |
| Global and local performance | p. 48 |
| Takt time, labor requirements, and line design | p. 50 |
| The minimum required number of assemblers | p. 50 |
| Assembler job design issues with short takt times | p. 52 |
| Assembler job design issues with long takt times | p. 55 |
| Assembly concepts | p. 59 |
| Visualizing the assembly process | p. 61 |
| Needs and evaluation criteria for visualization tools | p. 62 |
| The problem with facility blueprints | p. 63 |
| Lists and assembly master tables | p. 67 |
| Abstract flow diagrams and their limitations | p. 70 |
| Layout diagrams with flows | p. 75 |
| Two-dimensional diagrams | p. 75 |
| Three-dimensional drawings | p. 78 |
| Integration of text and drawings | p. 79 |
| Photographs | p. 79 |
| Impact of digital photography | p. 79 |
| Shop floor photography guidelines | p. 80 |
| Video recordings | p. 81 |
| Cardboard mock-ups | p. 81 |
| Discrete-event simulations | p. 82 |
| The concept of the assembly line | p. 85 |
| What is an assembly line? | p. 86 |
| Bench assembly versus the assembly line | p. 87 |
| Why assembly lines are still controversial | p. 88 |
| Comparing bench assembly with line assembly | p. 89 |
| Exceptions: where the bench still wins | p. 92 |
| Assembly lines, assembly cells, and line segments | p. 93 |
| Assembly and subassembly | p. 97 |
| All assembly work done in one single line | p. 97 |
| Final assembly line with subassembly feeder lines | p. 98 |
| Modular assembly | p. 99 |
| Pros and cons of subassembly/feeder lines | p. 101 |
| Collecting assembly time data | p. 103 |
| Why this needs attention | p. 103 |
| Data collection methods | p. 104 |
| Current status of time and motion studies in manufacturing | p. 105 |
| Predetermined time standards in the automobile industry | p. 105 |
| MTM and MOST | p. 107 |
| Time studies with video recordings | p. 111 |
| Line balancing | p. 113 |
| Assembly line balancing | p. 114 |
| Rebalancing a dedicated line | p. 115 |
| Multiproduct lines with batch versus leveled sequencing | p. 119 |
| Balancing assembly time among products on a mixed-flow line | p. 121 |
| Deliberate imbalances | p. 122 |
| Detailed design | p. 125 |
| Assembly station sizing | p. 127 |
| Issues with assembly station sizing | p. 128 |
| Assembly stations for small products | p. 128 |
| Assembly stations for large products | p. 132 |
| Ergonomics and safety | p. 136 |
| Standing versus sitting | p. 136 |
| Work height and assembler height | p. 139 |
| Stations with required dwell times | p. 140 |
| Detailed design of assembly stations | p. 143 |
| Issues with assembly station details | p. 144 |
| Assembly fixtures | p. 144 |
| Fixtures for manual assembly | p. 144 |
| Fixtures for mechanized or automated assembly | p. 149 |
| In-line mechanical automation | p. 151 |
| Handheld tools | p. 152 |
| Tools attached to the station and not to the assembler | p. 152 |
| Tool positioning and orientation | p. 154 |
| Assembly instructions | p. 157 |
| Instruction sheets | p. 157 |
| Contents of instruction sheets for manual assembly | p. 158 |
| Content of instruction sheets for mechanized assembly | p. 161 |
| Instruction sheets for mixed-flow assembly | p. 162 |
| Authoring instruction sheets | p. 163 |
| Use of information technology | p. 163 |
| Visible management | p. 164 |
| Self-explanatory devices, markings, and color codes | p. 164 |
| Tower lights, stop ropes, and other types of andons | p. 166 |
| Counters and production monitors | p. 168 |
| Part presentation | p. 171 |
| Scope and purpose | p. 172 |
| Part presentation requirements | p. 172 |
| Controversies about part presentation | p. 175 |
| Key principles of part presentation | p. 176 |
| Removal of packaging materials before delivery | p. 176 |
| Location within arm's reach of the assembler | p. 178 |
| Orientation | p. 179 |
| Adjustments to specific part characteristics | p. 181 |
| Matching quantities | p. 182 |
| Containers with dunnage for counting | p. 184 |
| Kitting versus line-side supply | p. 185 |
| Single-piece presentation and water spiders | p. 186 |
| Single-piece presentation | p. 187 |
| Water spiders and supermarkets | p. 189 |
| Conveyance between stations | p. 193 |
| Issues with conveyance systems | p. 194 |
| Goals for the conveyance system | p. 196 |
| A few types of conveyance systems | p. 197 |
| Unpowered conveyance | p. 197 |
| Powered conveyance | p. 199 |
| Assembly cells | p. 201 |
| About assembly cells | p. 202 |
| The motivation for cell conversion | p. 203 |
| Part supply to assembly cells | p. 206 |
| Range of applicability of the U-shape | p. 208 |
| Pseudo U-shaped cells | p. 210 |
| Overall shape of assembly lines | p. 211 |
| Beyond cells | p. 211 |
| Car and related assembly lines | p. 212 |
| Airplane assembly lines | p. 218 |
| Assembly quality | p. 221 |
| Preventing picking errors | p. 223 |
| About this chapter | p. 224 |
| Mistake-proofing assembly operations | p. 225 |
| Approaches to automatic identification | p. 226 |
| Using kit pallets and product fixtures to prevent mistakes | p. 228 |
| Mistake-proofing lineside picking | p. 231 |
| Mistake-proofing the kitting process | p. 235 |
| From stores to the line | p. 237 |
| Storage and retrieval | p. 238 |
| Naming items to avoid confusion | p. 240 |
| From the supplier to the dock | p. 242 |
| Inspection, test, and rework operations | p. 243 |
| The issues of inspection, test, and rework | p. 244 |
| The literature | p. 246 |
| The quality control literature | p. 246 |
| The lean manufacturing literature | p. 246 |
| The general literature on assembly | p. 247 |
| Is self-inspection possible? | p. 247 |
| Inspection and test sequencing | p. 249 |
| Sequencing by decreasing figure of merit and its limitations | p. 250 |
| Sequencing by induction | p. 252 |
| Testing multiple units at once | p. 254 |
| Designing automatic binning operations | p. 256 |
| Rework operations | p. 257 |
| Self-inflicted rework | p. 258 |
| Rework operations | p. 259 |
| Bibliography | p. 263 |
| Books in English | p. 264 |
| Books in Japanese | p. 265 |
| Books in German | p. 265 |
| Books in French | p. 266 |
| Index | p. 267 |
| Table of Contents provided by Syndetics. All Rights Reserved. |
