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Materials flow improvement in a lean assembly line: a case study

Rosario Domingo (Department of Manufacturing Engineering, National Distance University of Spain (UNED), Madrid, Spain)
Roberto Alvarez (Department of Industrial Engineering, Antonio Nebrija University, Madrid, Spain)
Marta Melodía Peña (Department of Industrial Engineering, Antonio Nebrija University, Madrid, Spain)
Roque Calvo (Department of Manufacturing Engineering, National Distance University of Spain (UNED), Madrid, Spain)

Assembly Automation

ISSN: 0144-5154

Article publication date: 24 April 2007

11223

Abstract

Purpose

This paper seeks to analyse the internal materials flow in lean manufacturing in an assembly line of the Bosch factory, located in Spain. The objective is to develop a handling system in a small space, capable of solving the problems of accumulated intermediate stocks of parts. An improvement is proposed adopting the milkrun handling system, while verifying the advances by means of lean metrics.

Design/methodology/approach

Based on this case study, the paper identifies data from value stream mapping and uses lean metrics, such as dock‐to‐dock time and lean rate. The case study develops a timetable and routing analysis for the milkrun to improve materials flow.

Findings

The proposed logistics allows an improvement of lean metrics, without modifying the layout and production planning. The routing flexibility of the milkrun reduced stocks, work‐in‐process and dock‐to‐dock time, while increasing lean rate.

Research limitations/implications

The findings are limited due to the focused nature of the case study. Although the solution is designed for a particular plant, the methodology is fully exportable.

Practical implications

The paper shows a real case study illustrative for systems management. This research shows significant benefit associated with the implementation of lean programs.

Originality/value

It details how the application of lean manufacturing tools could necessitate a study of materials handling to improve lean metrics.

Keywords

Citation

Domingo, R., Alvarez, R., Melodía Peña, M. and Calvo, R. (2007), "Materials flow improvement in a lean assembly line: a case study", Assembly Automation, Vol. 27 No. 2, pp. 141-147. https://doi.org/10.1108/01445150710733379

Publisher

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Emerald Group Publishing Limited

Copyright © 2007, Emerald Group Publishing Limited

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