A truly flexible assembly plant could produce cars, aircraft engines, refrigerators, cell phones and bagpipes on the same line. However, that type of scenario probably will never happen, because there are limits to flexibility. In fact, the most flexible type of factory may be a disposable factory.
The word “flexible” is defined many different ways by different manufacturers. That inconsistency can make it difficult to measure and monitor the effectiveness of flexible assembly lines.
No matter where or how it’s applied, the ultimate goal of flexible manufacturing is always the same: Greater responsiveness to customer demands, in addition to reduced changeover time and quicker time to market. But, exactly how much equipment reconfiguring and reuse can be done, and how much it costs, is subject to debate. Manufacturing engineers must address several myths and misperceptions that surround flexibility.
Many assembly lines are currently running much slower than this time last year. As a result, there’s a lot more idle time on plant floors these days. Keeping employees busy is crucial to keep workplace morale and productivity high.
Domestically imposed costs, such as health care insurance and litigation, harm American manufacturers more than offshore competition from China and other low-cost countries. But, other factors also affect the ability of our assembly lines to compete in today's global market.
According to most forecasts, 2009 is shaping up to be one of the most difficult years that manufacturers have faced in the last seven decades. To survive and thrive in this challenging economy, engineers must renew their efforts to reduce production costs, increase productivity, shorten time to market and improve product quality. Here are some practical tips and suggestions from leading experts.
Flexible assembly lines allow companies to react quickly to shifting customer demands and short product life cycles. As markets increasingly become less predictable, flexibility will become even more critical to manufacturers.
In the fast-paced world of packaging lines, success or failure depends on the ability to make quick changes. Like death and taxes, changeover is inevitable, and the need for speed has never been more crucial to the consumer goods industry.
These days, it seems that just about everyone is trying to get in on all the federal handouts and economic stimulus incentives that are being kicked around the marble halls of Washington, DC. How about an “Accelerated Retirement of Inefficient Assembly Lines Act”? It would allow American manufacturers to receive some type of monetary (or tax) incentive for scrapping old conveyors, fixtures, parts feeders, robots, screwdrivers, workstations and other production equipment.
