Optimizing flow and minimizing waste are two of the basic elements of lean manufacturing. Those concepts also play a critical role in laying out assembly lines.

WARREN, MI—Chrysler engineers revamped more than 350 workstations at a 76-year-old assembly plant here to boost production of the popular Ram pickup truck.

Lean workstations are designed for minimal wasted motion, which refers to any unnecessary time and effort required to assemble a product. Excessive twists or turns, uncomfortable reaches or pickups, and unnecessary walking all contribute to wasted motion.