In my workplace we build very large machines made up of smaller assemblies, each of these

smaller assemblies is built in its own area and some are more complex than others. Often the  manufacturing process will be delayed waiting for the completion of a complex assembly. The  challenge that we have is how can we reduce the time needed to build the more complex  assemblies. All workstations are similar containing parts racks, tool boxes and work benches.

For this problem we will apply mind mapping to help us find and solve the largest and

most glaring problems first. What is happening now? We assembled a team with diverse talents  from all  across the business to observe the build process.

Parts for the assembly are delivered in bins randomly, the assembler must search the bins

for parts needed in sequence. Sometimes there are variations in the assemblies requiring that the  assembler leave the area to get hardware. The assembler spends a lot of time bending over to work  on the assembly which is uncomfortable and causes fatigue. During brainstorming and observing  the assembler, we asked what if?

What if we changed the way parts are presented? What if we assembled all hardware in

one place? What if we made assembler comfort a priority? We asked assemblers what they would  like to make their job more efficient and they agreed that our findings were a great place to start.

All of these seem like good places to start and all seem feasible. So we will prototype our

new process. First we will present all the parts in their build sequence eliminating rummaging  through bins. Next we will gather and organize all hardware that may be needed into bins on a rack  in the workstation to eliminate the assembler having to walk all over to find it. Then we will raise  the work surface so that the assembler isn’t bending and can easily see and reach his work reducing  fatigue.

Indeed the prototype reduced the time taken to build an assembly considerably. We were

able to reduce unnecessary movement, We reduced ergonomic stress , The assembler was happy to  have a more organized work area and took pride in the improvement in his productivity. While  observing the new process it was decided to repeat the mind mapping process again to uncover  even more opportunities for improvement.


In my workplace we build very large machines made up of smaller assemblies , each of these smaller assemblies is built in its own area and some are more complex than others . Often the manufacturing process will be delayed waiting for the completion of a complex assembly . The challenge that we have is how can we reduce the time needed to build the more complex assemblies . All workstations are similar containing parts racks , tool boxes and work benches . For this problem we will apply mind mapping to help us find and solve the largest and most glaring problems first . What is happening now ? We assembled a team with diverse talents from all across the business to observe the build process . Parts for the assembly are delivered in bins randomly , the assembler must search the bins for parts needed in sequence . Sometimes there are variations in the assemblies requiring that the assembler leave the area to get hardware . The assembler spends a lot of time bending over to work on the assembly which is uncomfortable and causes fatigue . During brainstorming and observing the assembler , we asked what if ? What if we changed the way parts are presented ? What if we assembled all hardware in one place ? What if we made assembler comfort a priority ? We asked assemblers what they would like to make their job more efficient and they agreed that our findings were a great place to start . All of these seem like good places to start and all seem feasible . So we will prototype our new process . First we will present all the parts in their build sequence eliminating rummaging through bins . Next we will gather and organize all hardware that may be needed into bins on a rack in the workstation to eliminate the assembler having to walk all over to find it . Then we will raise the work surface so that the assembler is n’t bending and can easily see and reach his work reducing fatigue . Indeed the prototype reduced the time taken to build an assembly considerably . We were able to reduce unnecessary movement , We reduced ergonomic stress , The assembler was happy to have a more organized work area and took pride in the improvement in his productivity . While observing the new process it was decided to repeat the mind mapping process again to uncover even more opportunities for improvement .