Production Line Redesign Case Study:
From Batch Processing to One-Piece Flow
This production line redesign case study shows how ATC translated a customer’s one-piece-flow concept into a practical production system that doubled maximum daily output and reduced cycle time by 42%.
Overview
A manufacturing customer needed to redesign an existing production process that had become difficult to scale. The existing layout relied heavily on batch processing and was affected by high WIP, rework, material shortages and process complexity.
Client
Manufacturing customer.
Industry
Advanced Manufacturing.
Our Role
ATC translated the customer’s internally tested one-piece-flow concept into a practical, manufacturable production-line design, then engineered and manufactured the physical system required to support it.
The Challenges
The existing process had become difficult to scale.
Key issues included:
- high levels of WIP
- batch processing
- material shortages disrupting flow
- variable work methods
- rework
- complex operator movement
- a production system that was difficult to expand efficiently
ATC’s Production Line Redesign Approach
ATC developed the physical production line layout around the required process sequence and engineered the equipment needed to support the new flow.
The solution incorporated modular assembly workstations, feeder stations, integrated quality stations, flow racks, tooling and point-of-use material presentation.
The layout was developed around operator positioning, material presentation, ergonomics, access, quality requirements and the interfaces between each stage of the process.
Production Line Redesign Results
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Maximum daily output: 100 → 200 units
-
Cycle time: 55 → 32 minutes
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Operator requirement: 82 → 40
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Number of stations: 42 → 20
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Operator onboarding time: 12 weeks → 4 weeks
What this demonstrates
This production line redesign case study demonstrates how layout, equipment engineering and material flow can be developed as one integrated production system. The customer defined and tested the one-piece-flow concept; ATC engineered and manufactured the physical system that made it workable.
Engineered-to-order production line layout developed to support one-piece flow, point-of-use material presentation and improved operator movement.
Planning a new production line or redesigning an existing one?
ATC designs and manufactures engineered-to-order production lines, workstations and material-flow systems around the way your process needs to work.
