Study on implementation of one-piece lean line design using simulation techniques: A practical approach (original) (raw)
Related papers
This paper discusses the simulation study carried out for proposing one-piece lean line layout with features of Lean Manufacturing. The lean initiatives that can be addressed are, introducing Kanban replenishment system, better work-in-process, changing the layout, visual management techniques, standardized work for the reduction of cycle time, number of workers, number of setups. To improve the layout in a pump manufacturing industry, VISIO 2007 and Pro Model-Process Simulator Software are used. Pro Model simulation modeling software is a powerful yet easy-to-use simulation tools for modeling all types of systems and processes. Pro Model software is designed to model manufacturing systems ranging from small job shops and machining cells to large mass production, flexible manufacturing systems, and supply chain systems. The study has discussed the lacuna in the existing flow line and has suggested a new one-piece lean line design using the simulation software. The validation is carried out by creating the wooden prototypes representing the cells and involving the workers to do the assembly of the pump. Standard time study charts are used to calculate the cycle time and change over time.
OPTIMISATION OF A PRODUCTION LINE USING SIMULATION AND LEAN TECHNIQUES
This paper presents the use of simulation to assist the decision-making process involved in implementing lean manufacturing principles at a carton box die factory. The paper describes the application of discrete event simulation to improve and optimise the performance of the carton box die assembly line. Simulation experiments measure each system's resource requirements and performance, quantifying benefits to be derived from applying the principles of lean manufacturing. In this study, Simio is used to model and simulate different experimental scenarios in order to quantify the impact of selected input parameters on objective functions such as lead time. Results show that changes in the layout can reduce workers' movements and increase productivity.
To days industries striving hard to find methods for low cost, high production in laser time. Lean manufacturing concepts are used by industries to reduce various wastes in manufacturing for competing the global market. This research work has been carried out as a case study at Emerson Climate Technologies (ETC) India Ltd. plant located at Atit with an objective of waste reduction. Effort is made to reduce motion waste in the shop floor by work combination technique. Research work shows house of the simple lean concept and advance simulation software in industry for eliminates non value added activities and operational wastes. Problems in current production line are identified, and analyzed with the help of WITNESS simulation software. Then the layout is modified, simulated and results are compared with current layout. The results show that one operator is elevated than the previous. It saves in operator’s salary, which is considerable saving in total revenue. Proposed layout successfully implemented in industry and results are validated.
IJERT-Application of Lean Line Concepts to Improve Efficiency of PE Pump Assembly Lines
International Journal of Engineering Research and Technology (IJERT), 2014
https://www.ijert.org/application-of-lean-line-concepts-to-improve-efficiency-of-pe-pump-assembly-lines https://www.ijert.org/research/application-of-lean-line-concepts-to-improve-efficiency-of-pe-pump-assembly-lines-IJERTV3IS061133.pdf This paper is concerned with implementation of lean line concepts in multi-cylinder fuel injection pump assembly lines in a multinational company 1. Presently, the plant has 8 assembly lines that run for 3 shifts a day, wherein a total of 264 operators assemble 5 types of pumps (2/3/4/5/6 cylinders). The company has employed batch production that has resulted in very long lead times for products. Assembly of each type of pump involves 26 operations. All pumps require a similar sequence of operations, but more the number of cylinders in the pump being assembled larger would be the assembly time due to increased work content. Due to frequent changes in the customer demand and reduction in the number of operations-thanks to Kaizen, the lines need to be frequently rebalanced vis-à-vis changes takt times. Our analysis showed that the variation in monthly demand for pumps over the past 39 periods is normally distributed. A target production capacity to meet the monthly demand for at least 90% of the times was set. This monthly production requirement was converted into daily demand requirements and the corresponding takt times and Planned Cycle Times (PCTs) for various types of pump assembly were calculated. In our lean approach we divided each U-shaped assembly line into cells each with a set of tasks allocated to an operator and performed in a loop. The sum of task times in a loop is closely matched with the PCT of the pump type being assembled. When the assembly lines were balanced with this new PCTs, the number of operators drastically required. A production schedule combining both dedicated and mixed model production is proposed to produce every product every day in small batches as per its daily demand. The improved production schedule prepared required only 202 assembly operators as compared to 264 of the present practice. In other words, 62 operators are available for reallocation to other jobs which represented a huge saving of 23.5% workforce.
IJERT-Performance Analysis of Single Flow line Manufacturing -A Modeling Simulation approach
International Journal of Engineering Research and Technology (IJERT), 2013
https://www.ijert.org/performance-analysis-of-single-flow-line-manufacturing-a-modeling-simulation-approach https://www.ijert.org/research/performance-analysis-of-single-flow-line-manufacturing-a-modeling-simulation-approach-IJERTV2IS80433.pdf The flow line manufacturing with pull production control mechanisms in multi stage manufacturing systems has received much attention in the past decade. These systems are derived using the concept of just in time (JIT) manufacturing whose objective is that material should be produced in right quantity at right time at right place. The paper focuses on the performance of Extended Kanban control system (EKCS), Constant work in process (CONWIP) and kanban Control system (KCS) for a single flow line by considering three manufacturing stages. The above systems are modeled as a network diagram using technical computing software MATLAB SIMULINK. The simulation studies are analysed to evaluate the performance parameters like production rate, average waiting time, total work in process(WIP) and machine utilization. The demand is considered with exponential distribution mean time varying from 50min to 10min. The processing time at each manufacturing stage follows exponential distribution mean time of 15min. The flow line was simulated for 57600 minutes. At optimal demand rates, the pull control system with tighter coordination is EKCS with reference to production rate, total work in process (WIP) and average waiting time.
Redesigning an assembly line through lean manufacturing tools
The International Journal of Advanced Manufacturing Technology, 2009
Purpose-This paper seeks to analyse the internal materials flow in lean manufacturing in an assembly line of the Bosch factory, located in Spain. The objective is to develop a handling system in a small space, capable of solving the problems of accumulated intermediate stocks of parts. An improvement is proposed adopting the milkrun handling system, while verifying the advances by means of lean metrics. Design/methodology/approach-Based on this case study, the paper identifies data from value stream mapping and uses lean metrics, such as dock-to-dock time and lean rate. The case study develops a timetable and routing analysis for the milkrun to improve materials flow. Findings-The proposed logistics allows an improvement of lean metrics, without modifying the layout and production planning. The routing flexibility of the milkrun reduced stocks, work-in-process and dock-to-dock time, while increasing lean rate. Research limitations/implications-The findings are limited due to the focused nature of the case study. Although the solution is designed for a particular plant, the methodology is fully exportable. Practical implications-The paper shows a real case study illustrative for systems management. This research shows significant benefit associated with the implementation of lean programs. Originality/value-It details how the application of lean manufacturing tools could necessitate a study of materials handling to improve lean metrics.
Case Study of Utilization of Production Line by Using the Lean Manufacturing Methodology &Techniques
2015
Lean manufacturing has received a great deal of attention in its application to manufacturing companies. It is a set of tools and methodologies that aims for increased productivity; cycle time reduction and continuous elimination of all waste in the production process. In this paper a case study is presented in which bottlenecks are identified in the assembly shop of the Trucks and Buses manufacturing automobile company due to which the productivity was low. Thus, by using the methodology and tool of lean manufacturing reduced the bottlenecks through change in the design specification and tolerances in the component.
Line Balancing and facility optimization of Machine Shop with Work Study and Simulation Tool
Along with quantity the quality of finished part is examined strictly for the purpose and application of the finished part, the quality of production system is also important. Quality of production system in terms of utilization of machines and humans involved in system is important. Lean manufacturing concept is all about improving the performance continuously by eliminating the waste and to become competitive in production. The study focuses on a machine shop working in industrial sector with its sister companies, fluctuations in demands and also new critical developments for batch production are the main obstacles that shop is facing in their normal routine work. We are studying the newly introduced batch production system to increase the productivity and utilization of facilities involved in the system with work study and simulation tool. The process of machining is studied by method study, The standard times are calculated by time study, the proposed modifications in current working system are examined using simulation tool FlexSim. Simulation assists to study precisely the different manufacturing scenarios and machine arrangements; it gives sophisticated advantages than other methods like mathematical method. FlexSim is best way to compare the results obtained by certain changes in experiments in such cases.
[PDF]Optimisation of a Production Line using Simulation and
This paper presents the use of simulation to assist the decision-making process involved in implementing lean manufacturing principles at a carton box die factory. The paper describes the application of discrete event simulation to improve and optimise the performance of the carton box die assembly line. Simulation experiments measure each system's resource requirements and performance, quantifying benefits to be derived from applying the principles of lean manufacturing. In this study, Simio is used to model and simulate different experimental scenarios in order to quantify the impact of selected input parameters on objective functions such as lead time. Results show that changes in the layout can reduce workers' movements and increase productivity.
Transformation of a production/assembly washing machine lines into a lean manufacturing system
2009
The scope of this work is the complete re-organization of production flow according to the Lean Thinking philosophy for the industrial applications. The complete re-organization implementation of material flow management has been performed through the supermarket sizing which replenishment kanban logic has been adopted. To implement this strategy the goal is to achieve "Interdependent connected Processes" adopting the Pull System methodology in the Just in Time production environment. From the narrow sense the JIT manufacturing philosophy is to produce the right quantity at the right time with the right quantity level. In JIT the production is triggered by a kanban signal, which comes from the costumer order or the master production schedule, the signal then flowing backwards. By implementing JIT concepts in manufacturing, many of the practitioners experience advantages such as shorter lead times, fewer inventories, and higher quality. In the case study, developed in the Whirlpool Europe Naples factory, we have a first stage that consists of sizing the amount of "Kanban reintegration" codes, and the second stage in which we have simulated with ARENA and verified the progress of production flow in the hypothesized system, that has underlined the improvement of the business performances and great flexibility.