Breaking Through Plateaus in Precision Assembly Work

You reach a place where production work stalls. Even if you keep working consistently, you are not advancing. Slightly out of line parts; some adjustments on joints; same level work; this is not a time to stop but to focus in on the steps of production work. During assembly many steps merge to be one step so pay attention to steps before and during assembly.

Take a basic assembly step and work through it slowly with more time spent on each step. For example, try the step of putting two pieces together for a flush fit. Look at the pieces before putting them together and while putting them together. Note any small imperfections. Small differences will show up later and make adjustments difficult.

Most people work on the end product during this time and not on the process. If the joint does not look flush you would most likely want to force it to be so rather than fix it before putting the pieces together. The problem is the unevenness of surface and not flushness. If the joint does not look flush, the surfaces were not even or the edge was not flush. Before assembly look at the edges and surfaces on the individual pieces to ensure even surfaces and flush edges.

To get past a plateau, spend short periods of time repeatedly practicing a step of the production process. This could be 15-20 minutes of the same assembly step with the piece finished only at the end of that step. If something is not looking right, then take the piece apart, and put the steps together again. If you keep correcting at the end of the assembly process, you continue to learn and practice that sequence. Instead you want to get the steps right.

Sometimes you will be stalled and find your work is not changing. You may need to narrow the assembly process so the step becomes more exact. Maybe you want your flush fit to be tighter, maybe to only allow one adjustment once the pieces are together. With tighter constraints, there are fewer things you must focus on and you become more exact and precise in assembly.

With a deeper understanding and more control over the assembly steps you begin to go beyond this plateau. Your movements are more accurate to begin with and each step of the assembly follows from the previous. What began as a challenge or difficulty in a step is now a deeper understanding and more control of the step.