Optimization of motorcycle assembly processes based on lean manufacturing tools

Abstract

Global competition and economic dynamism force the assembly industry to look for productive philosophies of improvement, optimizing processes, and resources. The challenge in the optimization process involves finding tools that will grant an optimal process. This article proposes a process optimization through the application of Lean Manufacturing tools, with the necessary guidelines analyzed and verified by computational simulation in a motorcycle assembler. Firstly, applying a plant distribution, together with the change of productive system, allowed the reduction of distances, elimination of unnecessary movements, and reprocessing. Then, Pull System reduced the stock of both the product in process and the final product in the warehouse, avoiding the generation of future waste and expenses due to overproduction. Finally, the use of the 5S tool entailed maintaining order and cleanliness inside the plant to facilitate the management of internal resources. In the study reported, an average reduction of 40% in assembly time and an average increase in production of 30% of all motorcycle models that were part of the study are achieved.