Optimization of the Manual Insertion Process of Electric Motor Winders Using Lean Manufacturing Techniques

Abstract

During the manual insertion process analysis in electric motor production, process losses were identified. Using Lean Manufacturing tools and data collection, gaps in line balancing were mapped, resulting in low efficiency and desaturation in the insertion process. This study proposes the application of computer simulation and industrial layout restructuring based on NR-12 safety standards, in addition to implementing improvements such as the use of the spaghetti diagram and Kaizen techniques. The results indicate an average reduction of 30% in handling time, ergonomic improvements, better organization of the production space, and a reduction in intermediate inventories, consolidating an efficient and replicable model in other industrial units.