GE Transportation’s plant in Contagem, Brazil, has unveiled a new approach to manufacturing locomotives with a mixed-model moving assembly line.

This Lean Manufacturing system — one of the first in the industry — is said to be a more-efficient and sustainable approach to locomotive production. (www.getransportation.com)

Unlike traditional stationary production lines, the mixed-model moving line allows employees to assemble different locomotive configurations on the same line, as the units move slowly down the track.

It cuts lead times by about 20%, reduces inventory by $1.75 million and saves some 1,256m² of factory space.

Afonso Borges, GE Transportation’s industrial director, says lean processes can quickly accommodate different combinations and changes in demand, which is critical for sustainability.

“This new manufacturing approach allows for optimisation of the whole production process and supports the company’s lean culture.

“It enables us to improve the entire production system from end to end, and from the supplier to the final customer; this contributes to delivering better results, ensuring a more competitive and flexible business.”

To facilitate the transformation of the plant, the team constructed a scale model to test the moving-line concept; they also conducted more than 100 simulations to understand all ‘aspects and interferences’ that could affect the assembly line.

The line is now operational and moves at speeds up to 2.2m per hr during assembly, depending on the ‘takt’ time.

The production system also provides real-time visibility of the various manufacturing stages, which “fosters a problem-solving culture among the employees to quickly resolve issues as they arise”.