Hardworker & IronVale
IronVale
I’ve been tinkering with a modular exoskeleton that can be swapped out on the field, but the current assembly line still slows us down. How would you rework the workflow to cut the changeover time?
Hardworker
Cut the changeover by treating it like a puzzle you can solve in steps. First, break the whole swap into independent sub‑tasks and assign each to a dedicated station. Make sure each station has a custom jig that holds the same part in exactly the same spot so nobody has to guess. Second, create a single master checklist that the operator reads aloud while they work; that forces them to do everything in order and flags any missing step right away. Third, schedule the swap while the previous set is still finishing its own tasks—use a pull system so the new kit starts only when the old one is truly ready. Finally, keep a small buffer of spare parts at each station so you never wait for a part to arrive. Stick to those steps and you’ll shave the changeover from minutes to a few seconds.
IronVale
That’s a solid framework, but we can tighten it up a bit. The jigs are great – just make sure each one is keyed to the exact torque and alignment so the operator doesn’t have to double‑check. For the checklist, run a quick simulation first to see if any step can be overlapped; a few micro‑tasks can be done while the previous kit is still clearing its station. And for the pull system, a simple countdown timer on each station will keep the rhythm tight. If you keep the buffer to a minimum—just enough to cover a single failure—you’ll avoid over‑stocking and still stay on schedule. That should get you down to under five seconds.
Hardworker
Nice tweaks—keying the jigs to torque cuts the operator’s guesswork, and the countdown keeps everyone locked in. Running a micro‑task overlap simulation is smart; that’s where the real speed bump is hidden. Keep the buffer tight, just a spare kit, and you’ll hit that five‑second target without piling inventory. Keep the rhythm, and the line will flow like a well‑oiled machine.
IronVale
That’s the plan. Keep the jig specs locked, the timer humming, and the buffer lean. We’ll be switching faster than a sprint.We are done.That’s the plan. Keep the jig specs locked, the timer humming, and the buffer lean. We’ll be switching faster than a sprint.
Hardworker
Got it, all locked in. Let me know if anything needs tweaking.
IronVale
All set. I’ll ping you if any adjustments show up. Keep the cycle tight and we’ll stay on target.
Hardworker
Sounds good—just ping me if something changes. We'll keep the cycle tight.