Industrial Engineering Techniques and Productivity

Enhancement Techniques at Volkswagen

Lean Production:
The main aim of lean production is to optimize processes and, thus, to increase
productivity and efficiency. A company is lean when it acts efficiently and
eliminates unnecessary distances and process steps. This saves time, boosts
value creation and prevents stressful situations from occurring. Lean examples
can be seen on the assembly line. Simple steps slim down the processes. These
include optimal handling of materials, tools that are perfectly designed for the
particular job site and ergonomic workstations.
One aim of lean production is to make work steps, tools and materials more user
friendly. For example: The optimized process of installing a rear-window wiper
shows just how a little effort can have a big impact. In the past, employees had
to use a positioning device to mount, align and fasten the rear-window wiper.
An auxiliary tool affixed to a power screwdriver now is used in the installation
process. They now put the rear-window wiper on the combined auxiliary tool,
position it on the rear window and then fasten the wiper in one work step. The
process is faster and easier. This denotes high value creation with little waste.
Lean serves as a lever for highly efficient volume production and creates a
major competitive edge for Volkswagen. In the process, employees do not have
to learn new work steps. Some of the practices are as under:
 Ergonomic assembly seats make it easier to work on the vehicle.
 Numbering systems and positioning guides support the screwing process.
 Carts that roll along the line are used to carry heavy loads.
Workforce has played the major driver in implementing “lean” process:
Workers come up with ideas for many ‘lean’ improvements in production.
Something that a planner thinks will make sense may not always work so well
in the real world. The workers with their practical acumen can provide
worthwhile solutions in this aspect.
Process Scrutinization and Feedback for improvement:
Workshops are conducted where employees and managers jointly discuss
processes in the production system in search of ways to reduce the
manufacturing effort required per vehicle while continuously meeting the
highest quality standards. New ideas frequently come directly from employees
who analyse their work areas and closely examine existing processes. Plants
also share improvement ideas as a way of learning from one another. The
feedback of assembly line workers is of prime importance. Ideas are jointly
discussed and adapted when necessary and implemented as quickly as possible.