Integration of Lean Approaches to Manage a Manual Assembly System

Today, importance of flexibility and reconfigurability needs to be addressed when designing and implementing a cost-effective and responsive manufacturing system. Such a system should be able to accommodate dynamic changes of product varieties and production volumes by maximizing its production capability and minimizing its production costs, this is particularly useful for a SME (small and medium-sized enterprises) to remain competitive in the market. For a manual assembly line, it is always a good practice using a highly skilled workforce that each assembly worker is capable of performing multiple tasks. Ideally, each worker is fully trained to complete assigned tasks of a unit from start to finish. This paper presents a case study of incorporating 5S management rules into an assembly system using so-called skillful and dynamic walking workers as a combination of lean management approaches to improve productivity and efficiency of a shop floor production line at a local plant.