Cartoon Engineering, also known as a mock-up, despite its name being reminiscent of a cartoon TV channel, is a well-established tool used in process improvement.
The Challenge of Designing Machines and Production Lines
The design process for machines and production lines typically takes place in an office environment. Engineers and specialists use computers and specialized software to bring their own or the client’s vision to life. However, predicting every potential issue that may arise during the launch of a new production line or machine is nearly impossible.
Common challenges include:
- Optimization of the operator’s workstation
- Ergonomics and accessibility issues
- Coverage zone distribution
- Technical solutions required for safe, efficient, and customer-compliant operations
How Cartoon Engineering Helps Solve These Issues
To address these challenges, companies can use modern technologies such as virtual reality or the Cartoon Engineering method. This approach enables teams to transform a concept into a tangible 1:1 scale model of a new production line or workstation using simple materials like cardboard.
A cross-functional team, led by a Project Leader, collaborates to construct the layout of a production area, ensuring that all necessary aspects are considered before the final implementation.
Who Should Be Involved in a Cartoon Engineering Project?
A successful Cartoon Engineering project should include representatives from various departments directly involved in production, such as:
- Machine operators
- Lean specialists
- EHS (Environmental, Health and Safety) professionals
- Technical and engineering teams
- Quality and maintenance departments
- Supplier representatives (for integrating new solutions)
How to Start Implementation?
Phase 1: Kick-off Meeting
The Project Leader presents the main objectives of the new launch or modification. This includes:
- Reviewing process layouts
- Analyzing projected production volumes
- Assessing potential changeovers
- Examining DFMEA and customer requirements (e.g., packaging and quality control standards)
Phase 2: Physical Mock-Up Construction
The team constructs a full-scale (1:1) workstation or production line using simple materials. Ideally, this should be done at the final production site or at a supplier’s location. Key considerations include:
- Material flow direction
- Organization of surrounding components, tools, and documentation
- The mock-up should include all essential details, such as:
- Safety switches and curtains
- Cycle start triggers
- Electrical cabinets
- Buffer zones for materials and products
- Component feeders
- Control panels and monitors for machine operation
Once the mock-up is complete, the team performs a production simulation using real components.
Objectives of the Simulation
- Cycle time measurement
- Task observation and workflow analysis
- Ergonomic assessment of workstations
- Identification of waste (MUDA)
- Verification of operator safety risks
- Quality risk assessment
During the simulation, maintenance representatives evaluate tool placement, panel positions, and electrical cabinets to ensure accessibility for troubleshooting and preventive maintenance.
Recording and Implementing Improvements
All suggestions and anomalies must be documented. The team then:
- Develops an action plan
- Assigns responsibilities for corrective measures
- Sets deadlines for issue resolution
The Cartoon Engineering team should continue to meet after the mock-up phase to verify the effectiveness of the implemented improvements.
Cartoon Engineering – Benefits for the Company
- Simplicity & Cost-Effectiveness – Easy to implement with minimal investment
- Early-stage problem identification – Reduces costly modifications later in the project
- Cross-functional collaboration – Ensures all key perspectives are considered
- Improved ergonomics & efficiency – Optimizes workstations and production flow
- Fewer errors & failures – Prevents rework by refining processes before final implementation
What does this ultimately prevent? Expensive modifications to production lines, machines, or tools after they have already been delivered to the client.
Final Thoughts
Cartoon Engineering is a powerful yet simple method for refining production line design and process optimization. By involving a diverse team early in the development phase, companies can enhance efficiency, minimize risks, and improve overall production quality.
Ryszard Budniok
