Abstract: A product goes through various processes in a production flow which is also known as assembly line in manufacturing process management. Toyota created a new concept which is known as lean concept in manufacturing industry. Today it is the leading model in manufacturing plants through the globe. The linear walking worker assembly line is a flexible assembly system where each worker travels down the line carrying out each assembly task at each station; and each worker accomplishes the assembly of a unit from start to finish. This paper attempts to combine the flexibility of the walking worker and lean in order to quantify the benefits from applying the shop floor principles of lean management.
Abstract: This paper mathematically analyses the varying
magnitude of production loss, which may occur due to idle time (inprocess
waiting time and traveling time) on a linear walking worker
assembly line. Within this flexible and reconfigurable assembly
system, each worker travels down the line carrying out each
assembly task at each station; and each worker accomplishes the
assembly of a unit from start to finish and then travels back to the
first station to start the assembly of a new product. This strategy of
system design attempts to combine the flexibility of the U-shaped
moving worker assembly cell with the efficiency of the conventional
fixed worker assembly line. The paper aims to evaluate the effect of
idle time that may offset the labor efficiency of each walking worker
providing an insight into the mechanism of such a flexible and
reconfigurable assembly system.