Process Analysis and Modelling of Operator Performance in Classical and Digitalized Assembly Workstations

Abstract

Strong competition in the automotive industry has required manufacturers to implement lean production, both with methods and techniques specific to Industry 4.0. At the same time, universities must provide graduates with specific skills for applying these new production methods and techniques. In this context, a lean learning factory was developed in the Pitesti University Center that allows students to learn about, experiment with, and research new lean manufacturing methods and techniques as well as Industry 4.0 in an environment similar to that of enterprises. The research presented in this study aimed to identify the minimum number of repetitions necessary to train operators to perform the same assembly operation while working at two differently organized workstations: one classic and the other including digital techniques. Several indicators were considered in our analysis, such as the number of errors, the number of stops, the effective duration of the work cycle, and the percentage ratio between the standard duration of cyclical activities and the effective duration of the work cycle. The evolution of these indicators was mathematically modelled by regression functions, using the least squares method. The obtained results also highlight the usefulness of applying the DOJO method as a lean-manufacturing-specific learning technique and the efficiency of implementing digital techniques in work organization.