Improvement of an Air-Conditioning Pipes Production Line for the Automotive Industry Using Lean and CONWIP Methodologies

The presented work is focused on applying continuous improvement tools to reduce waste and process variability throughout an air-conditioned pipe production line (PL), to determine the line’s capacity and improve efficiency so that the desired productivity levels can be achieved. The line’s processes were analyzed, together with the integrated application of continuous improvement and Lean tools to determine and improve its production capacity. Thus, a variability study was carried out, focused on balancing the PL, to reduce the main bottlenecks. After balancing, several improvements were performed in the line layout, improving the line efficiency, and reducing unnecessary employees’ movements. Simultaneously, the Constant Work-In-Progress (CONWIP) methodology was implemented facilitating the management of the component’s production before their entry into the PL. Other modifications were also implemented, both mechanically and in terms of documentation, to support production and contribute to the line’s increase in efficiency, quality, and safety. The results obtained are relevant, with an increase in the capacity of the line and its productivity and efficiency, from 28.81% to 47.21%, and an increase of 18% in the Overall Equipment Effectiveness (OEE).