This paper compares batch processing to one-piece flow manufacturing on a housed bearing assembly line at a regional bearing manufacturer. The study used time study data from the company’s internal assembly timestamp records alongside direct observation of the three-station line. Value stream mapping documented the current and future states of the process. Simulation results show that one-piece flow reduces cycle time by 38%, reduces lead time by 46%, reduces work-in-process inventory wait by 56%, and increases daily capacity by 62%, from 254 to 411 units per day. A workstation task redistribution is proposed that balances all three stations at 40 seconds per unit without adding staff.
Analysis of Batch vs. One-Piece Flow Manufacturing of Spherical Bearing Assembly Process
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