“Here's the Mercedes A-class assembly line.[1] Cycle time is about 40 seconds.”
Shows a car assembly line with fixtures and short cycle time
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It's not unusual. Here's the Mercedes A-class assembly line.[1] Cycle time is about 40 seconds. That's 720 cars in an 8 hour shift. It's not unusual to run two shifts of production, and do maintenance on the third. In some highly automated plants, maintenance is in the daytime, and production is at night, with few people around. That's more for small parts than entire cars. Production line design and tuning is all about cycle time. The line runs at the speed of the slowest station. Any operation that takes too long has to be broken up into successive operations, even if one station could do it. You can fan out the line to multiple stations if you absolutely have to have a long cycle, but that adds cost, takes up floor space, and is really tough to retrofit. It's not unusual, though, to redesign the slowest station if that will speed up the whole line. Take a look at that Mercedes assembly line. Note all the custom fixtures required, many with sensor and actuators attached. All those have to be designed, built, tested, and run through enough cycles that they behave reliably. One failure stops the whole line. [1] this video
