PRODUCTIVITY IMPROVEMENT THROUGH BOTTLENECK IDENTIFICATION AND ELIMINATION IN A PUMP ASSEMBLY LINE USING SIMULATION

2020 ◽  
Vol 13 (6) ◽  
Author(s):  
Jaiganesh Venkataramani ◽  
Kavinesh Sankaar
Keyword(s):  
Assembly Line ◽  
Productivity Improvement ◽  
Bottleneck Identification ◽  
Pump Assembly

A Productivity Improvement of a Cookware Assembly Line

2015 ◽  
Vol 799-800 ◽  
pp. 1398-1402 ◽  
Author(s):  
Jongrak Niamsawan ◽  
Suksan Prombanpong
Keyword(s):  
Cycle Time ◽  
Assembly Line ◽  
Line Balancing ◽  
Productivity Improvement ◽  
Motion Study ◽  
Machine Layout ◽  
Workplace Organization ◽  
Bottle Neck ◽  
Assembly Operations ◽  
Working Method

This research objective is to improve the productivity of cookware assembly line by means of time and distance reductions. The motion study and line balancing techniques were applied to the entire assembly operations. A bottle neck was identified to where the operation with inadequate machine layout and workplace organization, including the unbalanced workloads. The new workplace layout and new working method for operators were designed and implemented as well as balancing the assembly line. Specifically, the conveyor speed and duration between the consecutive workpieces in the production line were adjusted to 0.10 m/s and 50 cm, respectively. The number of operators needed in the process can be reduced from 14 persons to 11 persons. The cycle time for assembling process is decreased from 12 to 5 second.

Efficiency Enhancement in a Medium Scale Gearbox Manufacturing Company through Different Lean Tools - A Case Study

2018 ◽  
Vol 34 ◽  
pp. 128-138 ◽  
Author(s):  
V. Saravanan ◽  
S. Nallusamy ◽  
Abraham George
Keyword(s):  
Lean Manufacturing ◽  
Processing Time ◽  
Assembly Line ◽  
Value Added ◽  
Value Stream Mapping ◽  
Productivity Improvement ◽  
Medium Scale ◽  
Value Stream ◽  
Manufacturing Company

Productivity is an important parameter for all small and medium scale manufacturing industries. Lean manufacturing emerged as production strategy capable of increasing productivity by identifying and eliminating non value added activities. This article deals with productivity improvement in a pre-assembly line of gearbox manufacturing company with a case study using lean concepts like process flow chart, process Gantt chart and time study. This paper illustrates using a case study on how a value stream mapping has to be carried out in a planet carrier pre-assembly line. Value stream mapping and work standardization are the key tools used in lean manufacturing and lean transformation. It makes the process smoother, helps in reduction of lead time and ultimately increasing the productivity. From the observed results it was found that, the productivity has been increased from 7 pieces to 10 pieces in the first step assembly when the proposed VSM was implemented. The second step processing time was reduced by the execution of proposed value stream mapping with TAKT time of 126 minutes and 165 minutes of processing time for demand of 10 pieces were achieved and the overall processing time has been reduced by about 24%.

scholarly journals The incorporation of virtual ergonomics to improve the occupational safety condition in a factory

2018 ◽  
Vol 9 ◽  
pp. 14
Author(s):  
Karin Kandananond
Keyword(s):  
Manufacturing Process ◽  
Material Handling ◽  
Occupational Safety ◽  
Assembly Line ◽  
Assessment Methods ◽  
Shop Floor ◽  
Productivity Improvement ◽  
Safe Working Condition ◽  
Improved Design ◽  
Ergonomic Analysis

Proper manual material handling (MMH) is the important step leading to the occupational safety of the workers on the shop floor as well as the productivity improvement of the manufacturing process. The objectives of this study are the application of different risk assessment methods, the redesign of the workstation to reduce the occupational risk and the utilization of software package to validate the proposed interventions. As a result, an assembly line of a product is selected as the case study to validate the proposed agenda. Afterwards, four lifting assessment methods, i.e. NIOSH lift equation, Snook Psychophysical Table, OSU Lift guidelines and ACGIH/TLV, are used to assess the hazard risk in the assembly line. After these methods are performed, the results are introduced to recommend the newly designed working conditions, i.e. postures, movements and the barriers. To validate the improved design, new configurations are simulated by the virtual ergonomic program and the ergonomic analysis is performed. The important results, e.g. low back compression and percent of population capable, are calculated by the software to determine the appropriate values which are used as the guidelines for a safe working condition. Moreover, the manufacturing process is also simulated to improve that the ergonomic redesign of the shop floor environment and another consequence of the implementation leads to the significant increase of the productivity.

Assembly line productivity improvement as re-engineered by MOST

2016 ◽  
Vol 65 (7) ◽  
pp. 977-994 ◽  
Author(s):  
A.N. Mustafizul Karim ◽  
Saravanan Tanjong Tuan ◽  
H.M. Emrul Kays
Keyword(s):  
Assembly Line ◽  
Flow Analysis ◽  
Value Added ◽  
Poor Performance ◽  
Hand Tools ◽  
Rear Window ◽  
Productivity Improvement ◽  
Content Type ◽  
Time Standards ◽  
Work Method

Purpose The purpose of this paper is to address and solve operational problems of an automotive industry in reaching production target by adopting Maynard Operation Sequence Technique (MOST) as lean and productivity improvement strategies. Design/methodology/approach In the undertaken case of auto-car rear window assembly line, a recurring production shortfall in fulfilling the daily demand is seemingly due to inappropriate work method. Initial observation of the operations led to suspect certain lapses in initiatives to adopt the time standards, to reduce or eliminate non-value added motions, to design suitable aisle and to assign tasks among workstations in a balanced manner. Subsequently an attempt is made to pinpoint the causes of poor performance and the bottlenecks through process flow analysis and time study by applying MOST. The elemental tasks are closely examined for possible reduction of workstation times by choosing efficient work methods with ergonomic features. Thus appropriate hand tools, jigs and fixture with nominal investment are prescribed to incorporate in the assembly works. The operational changes as steered by the MOST application have enhanced the workflow with a shorter cycle time which led to a substantial increase in productivity. Findings The productivity of the assembly line is increased by more than 29 percent from the earlier capacity through the MOST application which is deemed to meet the current level of demand. Originality/value The adopted framework for recognizing the effectiveness of MOST to expose and rectify the flaws in work methods without much investment is expected to be beneficial for a manufacturer in securing the competitiveness.

scholarly journals Defect Reduction with the Use of Seven Quality Control Tools for Productivity Improvement at an Automobile Company

2019 ◽  
Vol 9 (2) ◽  
pp. 4044-4047 ◽  
Author(s):  
I. A. Memon ◽  
Q. B. Jamali ◽  
A. S. Jamali ◽  
M. K. Abbasi ◽  
N. A. Jamali ◽  
...  
Keyword(s):  
Assembly Line ◽  
Successful Implementation ◽  
Defect Level ◽  
Statistical Tools ◽  
Productivity Improvement ◽  
Defect Reduction ◽  
Pareto Chart ◽  
Service Companies ◽  
And Control ◽  
Cause And Effect Diagram

The goal of zero defects is pursued by many manufacturing and service companies. In this regard, statistical tools are being used for defect reduction leading to productivity improvement. In this work, seven traditional QC tools (flow chart, check sheet, histogram, Pareto chart, cause, and effect diagram, scatter diagram and control chart) have been developed and implemented in an automobile company to assess and improve the defect reduction level in the assembly line. Chassis and trim lined were selected for data collection to assess and improve the defect level for productivity improvement. It was found from the results that after the successful implementation of the QC tools, the defect level reduced by 90% (from 132 to 13 defects) at the chassis line. Similarly, the defect level was reduced by 80% (from 157 to 28 defects) at the trim line. The automobile company implemented only a few of the seven QC tools in their assembly line. It is suggested that the company may need to manage a mechanism for the implementation of all seven QC tools in every section of the company.

Development of a modular garment assembly line simulator

2020 ◽  
Vol 32 (5) ◽  
pp. 645-659
Author(s):  
Eung Tae Kim ◽  
Sungmin Kim
Keyword(s):  
Assembly Line ◽  
Productivity Improvement ◽  
Content Type ◽  
Production Methods ◽  
Final Assembly ◽  
Time Required ◽  
Actual Shape ◽  
Line Design ◽  
The Given ◽  
Optimum Production

PurposeThe purpose of this study is to develop a modular garment assembly line simulator that can be used for various production methods such as traditional mass production or modern small quantity batch production.Design/methodology/approachFor realistic simulation, the actual shape and sewing information of the garment patterns were used. The assembly line consists of process units including the cutter, preprocessor, module assembly, final assembly, finish, and stack units. Any number of units can be arranged and connected to form various layouts. The simulation can be run at an arbitrary speed.FindingsThis system can be used to estimate the time required to process the given order for a specific layout. Therefore, it can be utilized as the basis for optimum production line design.Originality/valueThis system is expected to be utilized by garment manufacturers for obtaining the productivity improvement, production cost reduction, and increased competitiveness.

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