Materials flow improvement in a lean assembly line: a case study

Purpose – This paper seeks to analyse the internal materials flow in lean manufacturing in an assembly line of the Bosch factory, located in Spain. The objective is to develop a handling system in a small space, capable of solving the problems of accumulated intermediate stocks of parts. An improvement is proposed adopting the milkrun handling system, while verifying the advances by means of lean metrics.Design/methodology/approach – Based on this case study, the paper identifies data from value stream mapping and uses lean metrics, such as dock‐to‐dock time and lean rate. The case study develops a timetable and routing analysis for the milkrun to improve materials flow.Findings – The proposed logistics allows an improvement of lean metrics, without modifying the layout and production planning. The routing flexibility of the milkrun reduced stocks, work‐in‐process and dock‐to‐dock time, while increasing lean rate.Research limitations/implications – The findings are limited due to the focused nature of the...

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