It is worth noting that all of these fixtures were built and debugged during the initial prototype stages, leading to a higher first-run rate. If something goes wrong, the line stops until it gets fixed. But the line doesn't usually stop because the fixtures are robust enough to prevent assembly errors from happening. Additionally, the fixtures are all ergonomically designed to help avoid carpal tunnel syndrome and back problems that traditionally plague assembly operators. Besides fixtures, JCI employs other in-line quality measures.
Operators use torque-sensing guns with visual indicators.
If fasteners are not run to the correct torque setting, a light above the line comes on and the line shuts down until an operator corrects the problem. Likewise, the continuity of the electrical system in the seat is tested as it moves on the conveyor by plugging a machine into the wiring harness. Each of the seats also passes through a color detection machine that verifies that all of the small plastic trim pieces match the color of the seat. A final quality step has the seat set in an automated fixture that moves the seat through a full range of motion to calibrate the power adjustment controls. While there is obviously more to any lean production scenario than what is presented here, the point is that lean techniques can be used to solve seemingly contradictory assembly demands.