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The purpose of this paper is twofold: first, a case study on applying lean principles in manufacturing operations to redesign and optimize an electronic device assembly process and its impact on performance and second, introducing cardboard prototyping as a Kaizen tool offering a novel approach to testing and simulating improvement scenarios.

The study employs value stream mapping, root cause analysis, and brainstorming tools to identify root causes of poor performance, followed by deploying a Kaizen event to redesign and optimize an electronic device assembly process. Using physical models, bottlenecks and opportunities for improvement were identified by the Kaizen approach at the workstations and assembly lines, enabling the testing of various scenarios and ideas. Changes in lead times, throughput, work in process inventory and assembly performance were analyzed and documented.

Pre- and post-improvement measures are provided to demonstrate the impact of the Kaizen event on the performance of the assembly cell. The study reveals that implementing lean tools and techniques reduced costs and increased throughput by reducing assembly cycle times, manufacturing lead time, space utilization, labor overtime and work-in-process inventory requirements.

This paper adds a new dimension to applying the Kaizen methodology in manufacturing processes by introducing cardboard prototyping, which offers a novel way of testing and simulating different scenarios for improvement. The paper describes the process implementation in detail, including the techniques and data utilized to improve the process.

This study seeks to present a simple assembly line design and its balance for a low‐volume manufacturing company.

The study presents experiences with the design and implementation of a simple assembly line. The implementation concerns three aspects; design and construction of the assembly line, the assembly analysis of the product, and then balancing of the line. It also discusses construction and implementation difficulties of this tactical tool in the case company.

The study presents some outcomes from the design, implementation, and balancing of an assembly line for SMEs.

The study is limited by the case company and its experience.

This study is not pure theoretical study, it has application stages for industry, and it provides some real interface for the people from SMEs.

The approach has an original value in respect of implementation of assembly line for a small manufacturing company which has many limitations.

A paper presented at the Paris Assembly Automation conference dealt with a typical project concerning assembly automation of an LPG gas valve which had not been designed for automatic assembly. A series of suggestions for design modifications were proposed with the purpose of simplifying assembly.

This paper aims to present a method for predicting dimensional variation in assembly processes of a wingbox structure concentrating on the assembly of skin panels to rib feet.

Finite element modelling and experimental tests are conducted on the rib structure based on the site measurement gathered from the Airbus assembly factory.

The results have shown that the simulated model has the capability of predicting to an acceptable degree of accuracy the overall geometrical variations of the ribs and skin panels, as well as the positional variations of each individual rib foot.

The authors believe that no previous research has offered a similar prediction method for large aerostructures.

THE increasing pressure of national and international competition is forcing firms to rationalise even further, especially in the field of assembly. In order to perform assembly tasks with the least possible expenditure of time, assembly facilities, space requirements and personnel, it has become necessary to include these objectives in the development stage of the product. Therefore, assembly‐oriented design now provides a good opportunity for rationalisation.

The Assembly Systems Unit at the Royal Institute of Technology and IVF Stockholm has developed several Flexible Automatic Assembly (FAA) cell solutions over the years (Mark I, Mark II, Mark IIF and Mark III). The industrial reality, however, clearly points out that the basic notions of flexibility must be extended and be enhanced without increasing the complexity. This has led our research team to revise the ideas and solutions available for manual and automatic assembly, resulting in the Hyper Flexible Automatic Assembly (HFAA) project. The paper describes the driving factors behind the needs and objectives for the HFAA project, as well as how it will present a standardised set of assembly process‐oriented system components. The paper also describes the new Mark IV application. This industrial HFAA system is being developed in order to test the concept’s industrial viability. The HFAA concept will allow the user to start from a manual assembly station and gradually add assembly equipment. The basic concepts of stepwise automation, standard assembly machine and sub‐batch principle emanate from our previous research.

Market turbulence forces assembly plants to constantly adjust their production volume of products, variants and quantities. At the same time, assembly plant managers must protect long‐term investments in the flexible assembly system. For reconfigurability and agility the best solution is the modular semi‐automatic approach by combining flexible automation and human skills. It gives managers possibility to adjust volume by adding new modules or to automate the manual tasks step by step. The control of material handling and information flow in the agile assembly system is important. To keep flexibility, the combination of an intelligent pallet, i.e. use of escort memory, carrying a single product together with other hardware providing paperless production even supports a lot size of one. The article shows how to create flexible capability and capacity in the final assembly systems.

To improve the flexibility of its assembly methods the Bakony Works in Hungary took out a manufacturing licence with Bosch. Some examples of where the system has been used are described.

The dividing line between the sensible and efficient use of assembly robots and that of dedicated automatic assembly machines requires detailed planning.

As competition grows in the robot field and as more sophisticated applications emerge, it has become necessary to accurately predict robot cycle time. Especially in the area of robot assembly applications, it is necessary to estimate times to balance multi‐arm systems and to economically compare robot assembly systems to alternate methods. Using the Unimate 6000 robot system as a model and manual time methods as a guide, a robot time and motion method is developed. Three time estimating methods are discussed starting with a simple, approximate one and finishing with a detailed, accurate one. All three methods can be adapted for use with applications other than assembly and will be further evaluated in the future with other robot systems.