Overview

An assembly cell is a special case of an assembly line, run by a single team of at most eight multifunction operators, with autonomous pacing. An assembly cellprovides all the benefits of an assembly line, and adds those of being run by a cohesive team, which not only improves job satisfaction and morale, but also raises quality consciousness. Most cells are U-shaped, with product units flowing around a long and narrow operator work area. This pattern supports flexible staffing, and the number of operators can easily be adjusted up or down with changes in demand.

Parts can be supplied to assembly cells directly through milk runs from the warehouse, or by a water spider / team leader from a supermarket, in small containers to each assembly station or as kits to the first station of the cell. The choices depend on the size of containers available from the warehouse, the network of transportation aisles, and the variety of products made in the cell.

U-shaped cells work for products that are small enough in at least two dimensions to support feeding parts across the assembly stations and do not require simultaneous assembly on two or more sides. Most manufactured goods meet these conditions, but there are notable exceptions, such as cars, large household appliances, production machinery, or airplanes. Where U-shaped cells do not apply, it is often possible to reap most of their benefits through "pseudo U-shaped cells," where the material flow pattern is different, but we still have...