Enhancing automotive seat production at Lear Corporation

Company overview

Lear is an international company in the automotive industry, specialising in the manufacture of passenger seats for automobiles. With a global presence and a reputation for innovation, Lear is committed to delivering high-quality, comfortable seating solutions to leading automotive manufacturers.

Executive summary

The implementation of the automated line has delivered substantial benefits for Lear, including:

• Enhanced product quality and process security, with correct assembly and insertion force assured by automation.
• Improved operator safety and comfort, thanks to ergonomic workstation design and the elimination of strenuous manual tasks.
• Increased production capacity and efficiency, with an OEE exceeding 85% and a cycle time of just 90 seconds per unit.

Project objectives

To further strengthen its position in the market and address evolving customer requirements, Lear initiated a project with the following main objectives:

• Secure the assembly process in terms of correct assembly and insertion force.
• Implement automatic functional testing of the product.
• Improve the ergonomics of operator workstations.

The challenge

Lear’s production line for comfort systems involved several manual operations, including the complex and physically demanding task of wire insertion. This not only posed ergonomic challenges for operators but also introduced variability in assembly quality and process reliability. The company sought a solution that would enhance both product quality and working conditions for its staff.

The solution

Lear collaborated with automation specialists to redesign the production line, focusing on process security, quality assurance, and operator well-being. The new system was designed to:

• Automate the difficult operation of wire insertion, ensuring consistent assembly and correct insertion force.
• Integrate automatic functional testing of each product, providing immediate feedback and quality assurance.
• Redesign operator workstations to improve ergonomics, reduce physical strain, and support efficient workflow.

Key achievements

High operational efficiency

The new line produces comfort systems with an overall equipment effectiveness (OEE) of over 85%, reflecting significant improvements in productivity and reliability.

Reduced cycle time

The cycle time for each unit has been reduced to 90 seconds, enabling Lear to increase throughput and better meet customer demand.

Automated wire insertion

The previously difficult and variable operation of inserting wires has been replaced with a fully automated process, ensuring consistent quality and reducing the risk of operator injury.