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ST-04 · Project dossier

Optimisation of a Heat Pump assembly line

FIT Voltaira · Tangier, TAC · final-year internshipMarch – June 2025

Increase the productivity of a heat pump assembly line, without adding staff.

Loading the 3D…

  1. D
  2. M
  3. A
  4. I
  5. C

Scroll: the line changes action by action

  1. DDefine

    Frame the problem

    How can the overall performance of Heat Pump line 2 be improved while using fewer resources, keeping the production volume and the quality standards?

    • DMAIC
    • 5W2H
    • SIPOC
    • Line concept
    • Go from 3 to 2 shifts without losing capacity
    • Balance the workload between workstations
    • Improve the ergonomics of the workstations
    • Reduce waste
    • Bring actual output closer to theoretical output
    • Set up simple monitoring to sustain the results

  2. MMeasure

    Measure the line

    Timing of operating times station by station, comparison with the customer takt time, identification of the bottleneck station, calculation of the theoretical output and follow-up of complaints.

    • Time Study
    • Takt time
    • Bottleneck station
    • Utilisation rate
    LINE BALANCING
    1. Step 1:
    2. Step 2:
    3. Step 3:
    4. Step 4:

  3. AAnalyze

    Find the causes

    Analysis of the causes of the low output (Ishikawa), ergonomic analysis of the critical workstations, study of the move from 3 to 2 shifts and 5 whys on the complaints.

    • Ishikawa (5M)
    • Ergonomic analysis
    • 5 whys
    Ishikawa · 5MCauses → effect

    Method

    • Unbalanced workload between workstations
    • Non-optimal sequence of operations
    • Bottleneck at one workstation
    • No error-proofing systems (poka-yoke)

    Environment

    • Poor ergonomics
    • Inefficient spatial organisation of the workstations

    Manpower

    • Insufficient training (multi-skilling)

    Material

    • Inefficient supply of the workstations

    Machine

    • Outdated components on the electrical test bench (worn cables, old connectors)

    EffectLow output

  4. IImprove· Wires insertion & tubes (1)

    New design of the Wires insertion workstation

    Ergonomic reorganisation of the workstation: tilted cable ducts, a clear work surface, logical storage of cables and components.

    • Ergonomics
    • Standardisation

  5. IImprove· PE preparation / PE Terminal Block

    Reorganisation of the PE Terminal Block workstation

    Reorganisation of the PE Terminal Block workstation.

    • Ergonomics

  6. IImprove· PE Terminal Assembly

    Smaller PE Terminal Assembly workstation

    The PE Terminal Assembly workstation is resized to 1 m wide.

    • Ergonomics
    • Layout

  7. IImprove· Transfer area

    Separating part numbers in the transfer area

    Between the Soldering and the Insertion workstations, part numbers are separated in the transfer area.

    • Visual management
    • Error-proofing

  8. IImprove· Shrinking

    Automated and standardised shrinking

    Manual heating of the heat-shrink sleeves is replaced by an automatic, standardised process, which clearly cuts the shrinking time for every sleeve size.

    • Automation
    • Standardisation

  9. IImprove· Wire cutting (supply)

    Komax Alpha 355 cutting machine

    An additional cutting machine to make the supply of cut wires to the lines more reliable.

    • Capacity
    • Supply
    • Relieve the existing machines by spreading production orders better
    • Cut waiting times during peaks in demand
    • Improve the supply of cut components to every line
    • Limit the risk of saturating the cutting workstation

  10. IImprove

    Rebalanced workstations and new layout

    Tasks are redistributed between the workstations of the line for an even workload and a steady flow.

    • Line balancing
    • Layout
    LINE BALANCING
    1. Step 1:
    2. Step 2:
    3. Step 3:
    4. Step 4:

  11. CControl

    Sustain the gains

    One control sheet per workstation: a compliance checklist filled in on the shop floor and a visual performance check, every week.

    • Workstation standard
    • Shop-floor audit
    Station control sheetWeekly
    Sustain the gains
    CheckpointOKNOK
    Cable supports in place✓□
    Cables not tangled✓□
    Work surface clear✓□
    Components within reach without twisting✓□
    Assembly order followed✓□
    Workstation clean and tidy✓□
RESULTS

What the project delivers

Hourly output
+33 %
with the same headcount
Overall efficiency
+7 pts
better use of resources
Organisation
3 → 2
shifts, with no loss of capacity
Ergonomics
Redesigned workstations
optimised movements, lower risk of MSDs
Balancing
Even workload
less idle time and fewer overloads
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