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Complexity reduction and kaizen events to balance manual assembly lines: an application in the field

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  • Violetta Giada Cannas
  • Margherita Pero
  • Rossella Pozzi
  • Tommaso Rossi

Abstract

Notwithstanding the existence of a broad research base on assembly line balancing (ALB), companies do not use the mathematical approaches developed in the literature to configure assembly lines. This article aims to fill the gap between research and application by presenting and testing in a real industrial context a methodology based on complexity reduction and kaizen events. First, the methodology supports reducing the complexity that affects real-life assembly systems in terms of the variety of, e.g. finished products, materials and parts. Next, the methodology proposes the conduction of kaizen events by using lean manufacturing tools, such as process analysis, time observation, waste identification, workstation standard documents and yamazumi charts. The methodology is successfully applied to a case study that describes its use in the confectionery process for a major chocolatier company along with the results of the application. The main contribution of this paper consists in presenting a method to manage the line balancing activity within everyday industrial realities, helping practitioners to improve and maintain the performance over time.

Suggested Citation

  • Violetta Giada Cannas & Margherita Pero & Rossella Pozzi & Tommaso Rossi, 2018. "Complexity reduction and kaizen events to balance manual assembly lines: an application in the field," International Journal of Production Research, Taylor & Francis Journals, vol. 56(11), pages 3914-3931, June.
    • Handle: RePEc:taf:tprsxx:v:56:y:2018:i:11:p:3914-3931
    DOI: 10.1080/00207543.2018.1427898
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    Cited by:

    1. José Carlos Sá & Manuel Reis & José Dinis-Carvalho & Francisco J. G. Silva & Gilberto Santos & Luis P. Ferreira & Vanda Lima, 2022. "The Development of an Excellence Model Integrating the Shingo Model and Sustainability," Sustainability, MDPI, vol. 14(15), pages 1-28, August.
    2. Varun Tripathi & Somnath Chattopadhyaya & Alok Bhadauria & Shubham Sharma & Changhe Li & Danil Yurievich Pimenov & Khaled Giasin & Sunpreet Singh & Girish Dutt Gautam, 2021. "An Agile System to Enhance Productivity through a Modified Value Stream Mapping Approach in Industry 4.0: A Novel Approach," Sustainability, MDPI, vol. 13(21), pages 1-31, October.
    3. Battaïa, Olga & Dolgui, Alexandre, 2022. "Hybridizations in line balancing problems: A comprehensive review on new trends and formulations," International Journal of Production Economics, Elsevier, vol. 250(C).

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