A Case Study on Productivity Improvement for Conveyor Assembly Production Line in Medium and Small-Sized Manufacturing Factories

A case-based research method was chosen with the aim to provide an exemplar of practice and test the proposition that the use of simulation can improve productivity. Three alternatives were performed by considering the aspects of operator, machine, and workstation to define productivity improvement alternatives for operation optimisation. The research determines the optimum result to improve the current operation system. The experiments on simulated and real data clearly indicate that the productivity improvement in the current performance can be achieved by re-allocating the number of operators and machines effectively instead of a combination. The paper presents a novel example of the use of simulation to estimate the production line performance. The paper highlights this method by addressing this operational issue and the likelihood of the success of the strategic decision to improve productivity.

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A Productivity Improvement of a Packing Line

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.789-790.1240 ◽

2015 ◽

Vol 789-790 ◽

pp. 1240-1244

Author(s):

Peeyapach Jitchaiyaphum ◽

Suksan Prombanpong

Keyword(s):

Production Line ◽

Assembly Line ◽

Waste Reduction ◽

Line Balancing ◽

Assembly Lines ◽

Customer Demand ◽

Productivity Improvement ◽

Manual Assembly ◽

Line Design

The purpose of this paper is to demonstrate a productivity improvement through waste reduction and line balancing. One of the obstacles of a manual assembly line nowadays is an awkward line design with over manpower, a lot of wastes, and low balance efficiency. As a result, the production line may not satisfy customer demand and ends up with low production line efficiency. This is due to the fact that this type of production line is operated by human and the customer demand or requirements are frequently fluctuated. Human workers are prone to make mistakes, inefficient, and unorganized. Thus, the major causes of production line down time are discussed with suggestion of remedy actions to improve the productivity. In addition, calculation of line balancing is demonstrated. One of the actual manual assembly lines will be used as a case study. It is found that after improvement line balance efficiency is increased from 46.49 to 86.66 percent with the productivity improvement of 159 percent.

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A Case Study on Layout Design of Cellular Assembly Production Line

Journal of the Korean Institute of Industrial Engineers ◽

10.7232/jkiie.2017.43.5.397 ◽

2017 ◽

Vol 43 (5) ◽

pp. 397-412 ◽

Cited By ~ 1

Author(s):

Joung Woo Lim ◽

Seong Hyeon Park ◽

Chan Woo Bae ◽

Jae Man Ban ◽

Young Hoon Lee

Keyword(s):

Production Line ◽

Layout Design ◽

Assembly Production

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Productivity improvement in the production line with lean manufacturing approach: case study PT. XYZ

MATEC Web of Conferences ◽

10.1051/matecconf/201815401093 ◽

2018 ◽

Vol 154 ◽

pp. 01093

Author(s):

Halimatussa’ diah ◽

Ali Parkhan ◽

Muchamad Sugarindra

Keyword(s):

Production Line ◽

Lean Manufacturing ◽

Textile Industry ◽

Value Added ◽

Value Stream Mapping ◽

Competitive Strategies ◽

Productivity Improvement ◽

Value Stream ◽

Current Production

The increaseing productivity is one of the competitive strategies that can be applied in a company in order to survive in an intense competitive presure. PT. XYZ is a textile industry manufacturing golf gloves and caddy bag. Every day, the company has a production target of 600 pieces per line. However, the desired target is not achieved that it will affect the delay in delivery of products to customers. In this research, a case study on implementing value stream mapping and Kaizen as the lean manufacturing concept is reported. The purpose of this study is to map the current production line, analyse and design the future value stream mapping by eliminating waste occured. It is obtained a lead time reduction as much as 440.4 seconds through eliminating 17 non-value added activities. Then, the output can be increased up to 21% which is equal to 502 pieces.

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Continuous Productivity Improvement Using IoE Data for Fault Monitoring: An Automotive Parts Production Line Case Study

Sensors ◽

10.3390/s21217366 ◽

2021 ◽

Vol 21 (21) ◽

pp. 7366

Author(s):

Yuchang Won ◽

Seunghyeon Kim ◽

Kyung-Joon Park ◽

Yongsoon Eun

Keyword(s):

Monitoring System ◽

Continuous Improvement ◽

Production System ◽

Production Line ◽

Production Systems ◽

Productivity Improvement ◽

Fault Monitoring ◽

Line Configuration ◽

Automotive Parts

This paper presents a case study of continuous productivity improvement of an automotive parts production line using Internet of Everything (IoE) data for fault monitoring. Continuous productivity improvement denotes an iterative process of analyzing and updating the production line configuration for productivity improvement based on measured data. Analysis for continuous improvement of a production system requires a set of data (machine uptime, downtime, cycle-time) that are not typically monitored by a conventional fault monitoring system. Although productivity improvement is a critical aspect for a manufacturing site, not many production systems are equipped with a dedicated data recording system towards continuous improvement. In this paper, we study the problem of how to derive the dataset required for continuous improvement from the measurement by a conventional fault monitoring system. In particular, we provide a case study of an automotive parts production line. Based on the data measured by the existing fault monitoring system, we model the production system and derive the dataset required for continuous improvement. Our approach provides the expected amount of improvement to operation managers in a numerical manner to help them make a decision on whether they should modify the line configuration or not.

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