Improving performance of lock assembly line using lean and simulation approach

Abstract

Assembly line optimisation is an important process. When the system is complex, mathematical modelling and design of experiments becomes difficult. Hence process simulation approach is adopted here. Contribution of this research is improvement of performance of assembly line by maximising the measurement of performances like cycle time, throughput, resource utilisation and also by reducing cost. Key features of this research are development of eight different models for different input variables without disturbing existing set up. This what-if analysis is done using Arena process simulation software. Effect of layout, resource distribution, combination of operations, time study, Maynard operation sequencing techniques (MOST) has been studied here. Combinational effect of all these parameters are difficult to analyse analytically, hence unique simulation approach is selected. MOST is useful to find value added and non-value added activities. Lean techniques like kaizen, total productive maintenance, line balancing, low cost automation are used for different scenarios.

Contact points between Lean Six Sigma and Industry 4.0: a systematic review and conceptual framework

“…The previous literature regarding the integration between operational excellence approaches and I4.0 claims that this symbiosis can expand the possibilities of improvement on the shop floor. There are several research streams about this specific theme, such as interaction between lean manufacturing practices and digital technologies, including the development of digital value stream mapping (Southard et al , 2012; Rane et al , 2017; Lugert et al , 2018), electronic kanbans (Kolberg and Zühlke, 2015; Sanders et al , 2016; Wagner et al , 2017; Ante et al , 2018) and digital production control (Nicoletti, 2013; Kolberg et al , 2017; Ma et al , 2017; Satoglu et al , 2018). In addition, some articles address the interaction between BDA and Six Sigma (Hoerl et al , 2014; Li et al , 2015; Laux et al , 2017; Mayr et al , 2018).…”

Lean Six Sigma in manufacturing process: a bibliometric study and research agenda

“…Its implementation of value stream mapping (Li et al, 2015;Sanders et al, 2016). There are also articles that study the use of the big data analytics software in the development of the Quality Function Deployment (QFD) and the use of simulation software for process optimization in LSS projects (Yang et al, 2015;Rane et al, 2017).…”

Material Study for Designing Portable Helmet

“…From the overall properties of D3o and Sorbothane material, the best suitable material for helmet to be designed will be D3O and Sorbothane material.It is proposed to model the helmet based on material finalized in this study [11] . Further, it will be simulated in order to validate the result [12] .…”