A Slovenian company has developed a battery-powered device for which a manufacturing process had to be designed. In this master thesis, we systematically designed a manual assembly process. Based on the product structure, we determined the sequence and flow of assembly operations. Also, assembly times were calculated using the Work-Factor method, and process balancing was performed. Furthermore, assembly stations were drafted and positioned them in the available space in such a manner that the material flow is organized and losses are as low as possible. In the next chapter, a comparison of our design and actual production system is presented in terms of assembly operations duration, assembly station design, and layout. We discovered that assembly times achieved under serial conditions are longer than we calculated. Consequently, we had to adjust work stations and production floor layout. In the end, a short cost analysis is carried out. The result of the thesis is therefore a designed and optimized production system based on manual assembly.
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