Development and Implementation of a Smart Single-Station Manual Assembly Cell for an Inexperienced Worker to Enhance Industrial Efficiency in an MSME

Micro, Small, and Medium Enterprises (MSMEs) often face low efficiency, high error rates, and operator fatigue in manual assembly. High turnover of inexperienced/novice workers worsens these issues. Automation is common in large industries, but affordable smart solutions for MSMEs are limited. This study addresses the gap by converting a Traditional Single-Station Manual Assembly Cell (SSMAC) into a Smart SSMAC i.e. Smart Assembly Table (SAT). The SAT/Smart SSMAC uses smart technologies to improve efficiency, reduce errors, and counter the effects of high attrition among novice workers. A design-based experimental method was used. The upgrade included a Programmable Logic Controller (PLC), a Human-Machine Interface (HMI), sensor-enabled bin racks, and a modular workstation layout. The SAT/Smart SSMAC was tested in an MSME with inexperienced/novice workers. Productivity, error rates, and labor cost efficiency were measured. Real-time monitoring and digital displays guided operators in part selection, placement, and cycle time adherence using video and alarms. Tests with five inexperienced/novice workers over 100 assembly cycles showed significant gains. Cycle time dropped by 22.5%, and operator errors fell by 71.43%. Meeting the target cycle time improved by 34.33%, and delays reduced by 69.69%. The upgrade cost INR 129,988. Labor cost per unit decreased by INR 11.38, giving a 35% reduction. The SAT/Smart SSMAC supports Industry 4.0 goals, enhances lean manufacturing, and retains human involvement. Future upgrades, such as predictive maintenance and augmented reality, could further increase its benefits. The system’s flexibility across skill levels and product complexities offers potential for broader application.