Abstract
Cold test stations are commonly arranged as sequential processes along a complete engine production line. The production line consists of several stations for engine building purposes, and before the engine exits the production line it passes through different validation and testing stations, such as leak testing stations, piston protrusion stations (known as torque to turn stations), and cold test stations. Each of these stations has a sequence of operation that is performed automatically or semi-automatic with the support of an operator. The waiting time until the engine finishes the operation in one station is called “cycle time”. The longer the cycle time the less efficient the production line. Cold testing stations are considered the most complicated and time-consuming, yet important test stations for engine and powertrain development. The lengthy cycle time affects the overall efficiency of the production line. This paper investigates the problem of the cycle time difference between consequent stations and its effect on the overall efficiency of the factory. New techniques and operations research methods are introduced aiming to recover from such a manufacturing obstacle. This research is investigating the limitations of a manufacturing operation standpoint. Each test station is treated as a block that simulates the actual station, and the overall factory workflow is described. Time-based equations governing block time, idling time, and utilization of the system are introduced, and the factory efficiencies are calculated and compared. After identifying the problem, a practical solution is explained.
Time-Based Factory Efficiency Analysis | I.C. Engine Assembly Line