Capacity and UPH Improvement with Lean Tool: A Case Study of Electric Assembly Line

The economic environment is becoming more competitive as the modern world develops. For this reason, it is crucial for manufacturing companies to continuously improve, optimize processes, and reduce costs to outperform their rivals. Lean manufacturing is known as a good way for the great majority of companies. In this study, lean technology to enhance a production line for family products with rechargeable items would be mentioned. Lean tools and other suitable methods like line balancing, Maynard Operation Sequencing Technique (MOST), Define – Measure – Analyze – Improve – Control (DMAIC) cycle and work elements would be used to detect waste and non-value added, improving, and decreasing production time while ensuring product quality. As a good practical result, units per hour (UPH) factor increased from 48 to 90, units person per hour (UPPH) factor from 5.3 to 6.0, and saving the business $28,000 annually.

Lean Manufacturing, Lean Line balancing, DMAIC, MOST, UPH, UPPH.

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