GE Transportation unveiled a new approach for locomotive production, with a mixed-model moving assembly line at its plant in Contagem, Brazil. Unlike traditional stationary production lines, the mixed-model moving line is designed for employees to assemble different locomotive configurations on the same line as the units slowly move down the track.
This new production system enables the plant to increase productivity and optimize the workforce, as well as reduce lead time and inventory. The assembly line cuts lead time by approximately 20 per cent, reduces inventory by USD 1.75 million and creates 1,256 square meters of space savings within the factory.
To facilitate the transformation of the plant, the team constructed a scale model to test the moving line concept. They conducted more than 100 simulations to understand all aspects and interferences that could affect the assembly line. This validation process enabled the team to define the flow, the layout and the ideal space to implement the production system in the factory.
Now, the moving line is operational and moves between 1.15 to 2.20 meters per hour during assembly depending on the takt time. The production system also provides real-time visibility to the various manufacturing stages, which fosters a problem-solving culture among the employees to quickly resolve issues as they arise. This attribute makes the line ideal for digital monitoring.
“The mixed-model moving line was born connected. This means that several sensors have been installed to show the progress of all locomotive manufacturing steps, so delays, problems and other data are visible in real time through software developed to manage the line. Thus, it is possible to follow the production even remotely,” Afonso Borges, GE Transportation’s Industrial Director said.
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