Lean Assembly & Testing Workstations
Design and implementation of modular assembly and testing workstations for serial production. The main objectives were to shorten process times, improve ergonomics, and optimize material and information flow across the production area.
The system was based on Beevatec modular pipe structures, enabling rapid reconfiguration and adaptation to changing product variants. The project applied Lean Manufacturing principles, focusing on waste reduction, visual management, and operator efficiency.
Each workstation integrated visual indicators and error-proofing (poka-yoke) features to ensure consistent product quality and process repeatability.
Responsibilities:
– Concept development and full 3D CAD design in SolidWorks,
– Coordination with suppliers and procurement of modular components,
– On-site assembly, testing, and fine-tuning of workstations,
– Operator training and handover to production teams,
– Continuous improvement and layout optimisation in collaboration with stakeholders.
The modular approach significantly increased flexibility and visibility on the shop floor, while reducing assembly cycle times and changeover effort.