Manufacturing Logistics – The Backbone of Assembly Line?

“In this article we shall discuss on Manufacturing Logistics. So, you may be wondering what logistics is doing within the manufacturing shop floor??”

In the overall supply chain, manufacturing is the most exciting part where all the raw materials are converted into the finished product. Let us think about an automotive industry shop floor. All small parts that you find in your car are assembled and converted into the car that you drive, in the manufacturing shop floor.

“Imagine a manufacturing shop floor.” In a manufacturing shop floor, you will find an assembly line. People working alongside the assembly line are called assemblers. The activity period of these assemblers as well as time required for each step in the assembly line is guided by the Takt Time. Takt Time depends on the actual demand of the product.

“Now let us discuss what does manufacturing logistics do in a manufacturing shop floor??”

Manufacturing logistics looks after the availability of each and every part needed for the assembler at the right time and at the right place. It ensures that the parts are available, takes replenishment decisions like whether to store the parts or get it just in time (JIT) from the supplier and present them at the right time to the assembler. The assembler remains in the station picks up the part and assembles them according to the instruction given to him.

“How important is manufacturing logistics??”

Manufacturing logistics is equally important as tact time and an assembler. This is because if the material is not available the assembly line is going to come to halt. A proper design ensures that the line does not stop and the production continues as per the plan.


There are three specific designs associated with manufacturing logistics: –


  • PFEP (Plan for Every Part) – PFEP documents all important aspects beginning from the supplier. The document consists of the location of the supplier, how the parts are being loaded, the batch size, the kind of truck that has been used, the dock where the product will arrive, the container where the products will be put after unloading of the parts like box, crates and others. It also takes decisions like whether the same trolley in which the parts came will be used or some different trolley is to be used. The PFEP also documents the way in which the parts are going to fit to the line. Hence, PFEP design is one most crucial step in the design of manufacturing logistics.


  • Line Side Storage – The line side storage ensures that the assembler gets all the required parts within their reach just by standing alongside the assembly line. The line side storage is designed so as to ensure that the assemblers get exactly the set of parts and products from the left-hand side storage and the right-hand side storage, that he needs to complete the activity in that particular station.


  • Point of use presentation – It is the most crucial step in the entire designing process of manufacturing logistics. As I said, the parts are being stored in the storages in every station. Point of use presentation takes care of the storage design that is needed such that it is efficient for the assembler to take and assemble it. It takes major decisions like the quantity of parts that has to be stored, where the parts to be kept like whether it is to be placed in a trolley or bin box or any other type of container and others.


I would like to conclude my article by saying that these three steps are the core engine in the design of manufacturing logistics for a Manufacturing assembly.”


These are the basics of manufacturing logistics. There are lot of other designs and nuances that are associated with it. For any queries, please write back to us at

Hesol Consulting: Logistics & Supply Chain
Hesol Consulting: Logistics & Supply Chain
Hesol Consulting is a Management Consulting Firm with a specialization at Supply Chain, Logistics and Warehousing. Hesol has completed 280+ Supply Chain Projects across 10+ Sectors at 14+ Countries. Visit for more information.

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