Assembly Line
Multi-station product assembly process from raw materials to finished goods
ManufacturingLead Time
29.0h
Cycle Time
7.75h
Wait Time
21.25h
PCE
19.0%
Stages
9
Bottleneck
Shipping
Value-Add vs Non-Value-Add
Value-Add (VA)
An activity is value-add if it meets all three criteria:
- The customer is willing to pay for it
- It transforms the product or service
- It is done right the first time
Examples: Assembly, diagnosis, treatment, coding, machining, testing
Non-Value-Add (NVA)
Activities that consume time or resources but don't add value from the customer's perspective:
- Waiting — queues, approvals, batching delays
- Transport — moving materials or information
- Motion — unnecessary movement of people
- Rework — correcting defects or errors
- Over-processing — doing more than required
Note: Some NVA is necessary (compliance, safety). Target unnecessary NVA first.
Process Timeline
Value-Add vs Non-Value-Add
Bottleneck Analysis
Stage Efficiency
| # | Stage | Cycle (h) | Wait (h) | VA | Resource | Defect % | Efficiency |
|---|---|---|---|---|---|---|---|
| 1 | Raw Material Receipt | 0.5 | 4.0 | VA | Warehouse | 2.0% | 11.1% |
| 2 | Material Inspection | 0.75 | 1.0 | VA | QC Inspector | 5.0% | 42.9% |
| 3 | Staging & Kitting | 0.5 | 2.0 | NVA | Material Handler | 3.0% | 20.0% |
| 4 | Station 1 — Sub-Assembly | 1.5 | 0.5 | VA | Operator A | 4.0% | 75.0% |
| 5 | Station 2 — Main Assembly | 2.0 | 0.25 | VA | Operator B | 6.0% | 88.9% |
| 6 | Station 3 — Testing | 0.75 | 0.5 | VA | Test Tech | 8.0% | 60.0% |
| 7 | Rework (if needed) | 1.0 | 4.0 | NVA | Rework Tech | 0.0% | 20.0% |
| 8 | Packaging | 0.5 | 1.0 | NVA | Packer | 1.0% | 33.3% |
| 9 | Shipping | 0.25 | 8.0 | NVA | Logistics | 2.0% | 3.0% |