The assembly procedure for the doors used on the Russian MC-21 passenger aircraft has been optimized by the Yakovlev Production Center in Komsomolsk-on-Amur. The modifications have changed both the organization of the production area and the way components are transported between assembly stages. The company says that the outcome has been a substantial increase in productivity, which has been achieved while simultaneously reducing the quantity of production space necessary.
From a “Push System” to a Continuous Flow
Previously, MC-21 door assembly was organized according to a production model typical of facilities using lean manufacturing principles and a so-called “push system.” In this method, materials and semi-finished components are transferred to the next workstation in accordance with a predetermined schedule, even if the latter is not yet prepared to process them.
An arrangement of this nature may result in a buildup of components between operations, unnecessary movement, and uneven workloads across workstations. One of the main objectives of the modernization was therefore to create a more logical and continuous movement of the product throughout the assembly process.
The solution was comparatively straightforward: the existing assembly jigs were modified and equipped with wheels. This eliminates considerable amounts of unnecessary handling by enabling the door assembly to transition from one operation to the next in conjunction with the jig.
As a result, the facility established a single continuous assembly flow. The redesigned jigs now conform to the shortest possible route between operations, which helps to reduce wasted time and ensures a more consistent burden across workstations.
A “Pit Stop” Instead of Waiting for Breakdowns
Maintenance of the assembly jigs was also prioritized. A “pit stop” system has been implemented to guarantee that maintenance is conducted in a systematic manner, rather than only after a malfunction occurs.
This is of particular significance in the aircraft manufacturing industry, as a malfunction at any point during the production process can have a major impact on the entire downstream process. The jigs can be maintained in a functional state, and the probability of unexpected delay can be reduced through scheduled maintenance.
Consequently, maintenance has evolved into an essential component of the production process, rather than a response to equipment malfunction.
Maintenance has therefore become an integral part of the production process rather than a reaction to equipment failure.
3D Printing for Greater Accuracy
The quick production of auxiliary fixtures and their adaptation to specific manufacturing requirements are made possible by the direct use of 3D printing within the production environment. This is particularly beneficial in the production of aircraft, where dimensional precision is indispensable.
Importantly, 3D printing has not been regarded as a standalone venture; rather, it has been integrated into the overarching endeavor to enhance the efficiency of the assembly process.
Turning the Workplace into a Training Environment
The changes have also extended to workforce organization. In addition to a mentoring system and greater usage of visual management, dedicated training areas have been implemented on the production floor.
This method facilitates the swift transfer of practical knowledge to new employees and the standardization of the execution of individual operations. Visual materials that appear directly at the workstation enable employees to adhere to the necessary sequence of operations without the need to exit the production area.
Additionally, workers have been furnished with the requisite equipment at their workstations. This minimizes the need for unnecessary movement and reduces the time that was previously devoted to the search for tools or necessary components.
Updating the Production Documentation
The optimization was accompanied by a major revision of the supporting documentation. Four instructions were revised, 12 regulations were authorized, and 548 process passports were created as part of the transformation.
This activity is crucial for guaranteeing the sustainability of the new production system. In addition to the physical reorganization of a production area, the new procedures must be formally documented to modify a manufacturing process. This facilitates the replication of the enhancements and establishes uniform standards for the execution of each operation.
Consequently, the optimization had an impact on various aspects of the production system, including the movement of assembly jigs, equipment maintenance, employee training, and regulatory documentation.
Productivity More Than Doubled
According to the Yakovlev Production Center, the results of the changes have been significant. The production space was freed up for other activities as a result of the 40% reduction in the number of workstations required.
Concurrently, the output per employee increased by 111%. In other words, productivity per worker increased by more than twofold in comparison to the previous level.
Additionally, the overall efficiency of the team increased by over twofold. It is particularly noteworthy that this improvement was not attributed to a single technical improvement. The improvements stemmed from simple measures like mobile assembly platforms, continuous production flow, scheduled maintenance, 3D printing, training, visual management, and conveniently located tools.
Minor modifications yield substantial outcomes
The rationalization of MC-21 door assembly in Komsomolsk-on-Amur demonstrates that the enhancement of industrial productivity does not necessitate the construction of new production facilities or a significant overhaul of equipment.
Changing the logic of the production process can yield substantial benefits in numerous instances. A more efficient production system emerges when components take the shortest route, tools are accessible to workers, equipment is proactively maintained, and operations are standardized and visualized.
This combination of measures has enabled the production center to increase productivity while simultaneously freeing up valuable floor space in the case of MC-21 door assembly.