Using Lean Thinking Principles To Reduce Wastes In Reconfiguration Of Car Radio Final Assembly Lines

Assembly lines are production systems designed to be oriented to the product and well known to be highly productive. Nevertheless, during this time-frame the product volumes could decrease and the assembly lines, previously very productive and efficient, becomes unproductive and inefficient. This happens in the car electronics components company where this study took place that due to customer´s demand decrease, produced volumes also decreased and provoked the appearance of wastes related with too much occupied space, unbalanced workstations, more capacity than needed, outdated standard work sheets, bottlenecks, to conclude, too many non-added value activities. This paper presents a reconfiguration proposal for two final assembly lines with the goal of adapt physically the lines to the actual production volumes and eliminate the existing wastes. The proposed reconfiguration translates into very positive gains for the company, namely, the release of 22% of the space occupied by the production lines, a reduction in the number of operators, a 50% increase in productivity for each of the lines and an increase in the utilization rate (23% for line 1 and 13% for line 2). In total, the monetary gains associated with these improvements were, approximately, of 125,600 m.u. per year.