Many companies will be assembling final assemblies with sub-components being brought in from suppliers, the final assembly forming a critical part of the product quality.  The flow of the assembly and sub-assembly to the line is critical to an efficient process.

Many assembly operations will be labour intensive and the balance of work to reach maximum throughput is critical. Gemba’s Modular GAIN4 solution addresses Assembly problems with the following features :

• Track production throughout the assembly process (GAIN4 Tracking)
• Record individual cycle times for assembly operations (GAIN4 Efficiency)
• Allow TAKT times to be created and monitored to meet customer demand (GAIN4 Andon)
• Assembly details and subcomponents to be recorded for lot traceability (GAIN4 Tracking)
• Deliver  Standard Operating Practice (SOPs) documents electronically to the line reducing paperwork (GAIN4 Efficiency)
• Identify rework at the stages in the assembly process (GAIN4 Tracking and Efficiency)
• Provide electronic Kanban systems (GAIN4 Andon)
• Records labour levels used at each stage of the assembly operation (GAIN4 Labour)

Benefits:

• Remove detailed paperwork from the assembly area for product traceability by collecting through barcode traceability systems
• Perform line balancing by recording individual operation times and allow Value Stream Maps to be created
• Meet customer demands by driving in real-time conformance to the daily plans via Large LCD scoreboards
• Ensure build compliance and optimize training of new staff by delivering product based SOPs directly to the work station by assembly based PC systems
• Remove stoppages due to shortage of assembly components by implementing electronic store Kanban systemIdentify the true cost of production by recording true labour usage and operation times