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Efficient Workstation Design: Key Insights from Gearbox Assembly

Discover the essential steps to optimize workstation design for high-demand manufacturing processes. Learn how to balance manual and automated tasks, ensure ergonomic efficiency, and meet tight TAKT Time requirements while maintaining cost-effectiveness.

<p>In modern manufacturing, efficiency is king. When Magna International requested a design for a workstation to assemble horizontal gearboxes, the challenge became a lesson in effective workstation design. This project not only involved adhering to rigorous production standards but also maintaining ergonomic safety and cost efficiency.</p>
<hr>
<h3><strong><img src="https://files-storage-l.nyc3.digitaloceanspaces.com/epic-essay/pjhB1fsKSYZQ7GDJd8GUGg12zIGB9Ofd0y0oR0pN.png" width="621" height="230"></strong></h3>
<h3><strong>Understanding the Scope</strong></h3>
<p>The project focuses on assembling left-hand (LH) and right-hand (RH) horizontal gearboxes with annual production requirements of <strong>680,000 units</strong> (340,000 each). The assembly involves a <strong>4-step process</strong> with manual and automated operations, ensuring precision in quality and output.</p>
<h4>Key BOM Components:</h4>
<table>
<thead>
<tr>
<th><strong>Part</strong></th>
<th><strong>Material</strong></th>
<th><strong>Quantity</strong></th>
<th><strong>Weight</strong></th>
</tr>
</thead>
<tbody>
<tr>
<td>Upper Shell</td>
<td>Zinc Die Cast</td>
<td>1 per unit</td>
<td>230 grams</td>
</tr>
<tr>
<td>Helical Gear</td>
<td>Nylon</td>
<td>1 per unit</td>
<td>70 grams</td>
</tr>
<tr>
<td>Grommet</td>
<td>Rubber</td>
<td>1 per unit</td>
<td>80 grams</td>
</tr>
<tr>
<td>Bushings</td>
<td>Bronze</td>
<td>2 per unit</td>
<td>100 grams</td>
</tr>
</tbody>
</table>
<hr>
<h3><strong>Steps to Optimize Workstation Design</strong></h3>
<h4><strong>1. Analyze Process Flow and Assumptions</strong></h4>
<ul>
<li><strong>Manual Handling:</strong> All components are small, making manual handling feasible.</li>
<li><strong>Ergonomic Requirements:</strong> Positioning parts and equipment at waist height minimizes strain.</li>
<li><strong>Quality Requirements:</strong> Ensure accurate assembly through visual inspection and automated testing.</li>
</ul>
<h4><strong>2. Conduct a “MOST” Study</strong></h4>
<p>Using the Maynard Operation Sequence Technique (MOST), each operation in the process flow was analyzed to determine cycle times:</p>
<ul>
<li><strong>Assembly (Op. #10):</strong> Manual placement of components.</li>
<li><strong>Staking (Op. #20):</strong> Automated press with manual setup.</li>
<li><strong>Greasing (Op. #30):</strong> Controlled automated application.</li>
<li><strong>Final Testing (Op. #40):</strong> Automated testing and packing.</li>
</ul>
<hr>
<h4><strong>3. Determine Daily Demand and TAKT Time</strong></h4>
<ul>
<li><strong>Customer Demand:</strong> 680,000 units annually translates to <strong>2,833 units/day</strong>.</li>
<li><strong>TAKT Time Calculation:</strong> <span class="katex-display"><span class="katex"><span class="katex-mathml">TAKT Time=Available Time per Day (in seconds)Daily Demand\text{TAKT Time} = \frac{\text{Available Time per Day (in seconds)}}{\text{Daily Demand}}</span><span class="katex-html" aria-hidden="true"><span class="base"><span class="mord text"><span class="mord">TAKT Time</span></span><span class="mrel">=</span></span><span class="base"><span class="mord"><span class="mfrac"><span class="vlist-t vlist-t2"><span class="vlist-r"><span class="vlist"><span class="mord text">Daily Demand</span><span class="mord text">Available Time per Day (in seconds)</span></span><span class="vlist-s"></span></span></span></span></span></span></span></span></span> With 21,600 seconds per shift, TAKT time is approximately <strong>7.62 seconds/unit</strong>.</li>
</ul>
<hr>
<h4><strong>4. Identify Bottlenecks</strong></h4>
<ul>
<li><strong>Cycle Time Analysis:</strong> Determine which operation limits overall capacity.</li>
<li><strong>Delay Time:</strong> Account for shift allowances like breaks and meetings.</li>
</ul>
<h4><strong>5. Balance the Work Cell</strong></h4>
<ul>
<li><strong>Manpower Allocation:</strong> Assign tasks to balance workloads across employees.</li>
<li><strong>Hourly Capacity Optimization:</strong> Match hourly output to TAKT requirements.</li>
</ul>
<hr>
<h4><strong>6. Estimate Standard Hour and Direct Labour Cost</strong></h4>
<ul>
<li><strong>Hourly Capacity:</strong> Calculate output based on cycle times.</li>
<li><strong>Direct Labour Cost:</strong> At $20/hour, optimize the number of workers to reduce overhead.</li>
</ul>
<h4><strong>7. Develop an Operating Plan</strong></h4>
<ul>
<li><strong>Number of Shifts:</strong> 3 shifts/day to meet demand.</li>
<li><strong>Employee Count:</strong> Determined by MOST cycle times and TAKT requirements.</li>
<li><strong>Equipment:</strong> Include automated presses and grease dispensers.</li>
</ul>
<hr>
<h3><strong>Key Takeaways</strong></h3>
<ol>
<li><strong>Efficiency through Design:</strong> Incorporate ergonomic and automation-friendly designs.</li>
<li><strong>Data-Driven Decisions:</strong> Use cycle time analysis and TAKT calculations to guide resource allocation.</li>
<li><strong>Balanced Workloads:</strong> Ensure tasks are evenly distributed to avoid bottlenecks.</li>
</ol>
<hr>
<h3><strong>Conclusion</strong></h3>
<p>This project highlights the importance of strategic workstation design in meeting high production demands while maintaining cost efficiency and product quality. Manufacturers can design workstations that meet both production and ergonomic goals by leveraging tools like the MOST analysis and TAKT calculations.</p>
<p><strong>Looking to optimize your workstation design for better efficiency?</strong> Visit <a href="#" rel="noopener">Epic-Essay.com</a> for in-depth solutions and guidance tailored to your manufacturing challenges!</p>

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Efficient Workstation Design: Key Insights from Gearbox Assembly

Discover the essential steps to optimize workstation design for high-demand manufacturing processes. Learn how to balance manual and automated tasks, ensure ergonomic efficiency, and meet tight TAKT Time requirements while maintaining cost-effectiveness.

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