Lean cell implementation in high mix, low volume manufacturing

Abstract: This thesis was conducted at Enics manufacturing unit in Västerås. This site
employs 360 people out of a total of 2400 globally. The site produces
electronics and is specialised toward low volumes and spare parts.
The site has problems with high inventory levels, long lead times and less
than preferred service level towards customers. This is the reason for the
project which will investigate if it possible to implement a cell configuration
with one piece flow for a part of the production process. The difficulties
consist of the high variation in products and process flows which makes
planning and grouping of products difficult.
To aid this project a Six Sigma methodology called DMAIC (Define-
Measure-Analyse-Improve-Control) was used. Tools and principles from
Lean manufacturing was also used and discussed. Data from the production
has also been collected by the author.
As a start a suggested product family was presented by Enics. Process
mapping was done for all products by using process maps, spaghetti
diagrams and value stream mapping. The initial product family had to be
dismissed and a new product family was chosen by analysing process flows
and demand for all products. This second product family was then analysed
in order to decide if a cell configuration was possible.
In the end the project concludes that a cell configuration with one piece flow
is feasible and it is partly implemented. A number of layout suggestions are
made for future development. A discussion regarding the problems the
company are facing follows before the author concludes that the company
should continue implementing the fundamental strategies from lean
manufacturing despite being a smaller company. Much of the principles are
applicable and possible despite the high product variation and lack of
resources in the company.