Integrating Assembly Lines based on Lean Line Design Concept

1 ISSN: 2278 1323. International Journal of Advanced Research in Computer Engineering & Technology (IJARCET). Volume 2, Issue 6, June 2013. Integrating Assembly Lines based on Lean Line Design Concept Ms. Surekha. S1, Dr. R. V Praveena Gowda2, Mr. Manoj Kulkarni3. Abstract the methods used to perform any manual In today s competitive business scenario operations or task & as a product of that manufacturing industries are under the analysis, let the standard time in which a pressure to reduce cost and cycle time. It is a worker should complete the task. lean manufacturing Concept with a systematic B.

2 Lean Line Design - Lean Line Design is a approach to identify and eliminate waste method for implementing manufacturing through continuous and sustained industries principles like process improvements by manufacturing the product orientation, perfect quality, at the pull of the customer in pursuit of standardization, flexibility, waste perfection. This paper is to Design and elimination, transparent process, associate Integrate Assembly Lines A and B based involvement etc. LLD technique is as on Lean Concept using MTM/UAS analysis shown in fig 1 while planning the new for determine the time and to identify the Design of manual and semi-automated improvement.

3 The study was carried out in 2 work systems this LLD technique is Assembly Lines in a reputed manufacturing required to result in the better line. The industry. The paper concentrates only on qualitative aim is to redesign production Assembly line and where Assembly line B is and logistics according to manufacturing to be accommodated into Assembly line A . industries criteria. The quantitative aim is The main focus of the paper is to study the to increase productivity and flexibility, as existing system and designing the new well as lowering the investment ratio, solution based on Lean Line Design Concept space requirements and through-put times.

4 Which would follow the standards of the manufacturing industry Keywords: Integration, manual work system, line balancing, manual time. Fig 1: LLD Technique Abbreviations: C. Approaches to LLD- Designing the lean LLD- Lean line Design CTT Customer takt time line means to rearrange the stations in the OEE- Overall equipment effectiveness existing line which would be meeting the PC/T- Planned cycle time manufacturing industries standards. [3]. OBC- Operator balance chart LLD which is used for rearranging is a SW- Standardized work step by step approach, the approaches flow CIP- Continuous improvement process is shown in fig 2.

5 I. Introduction The aim of the paper to integrate 2 Assembly Lines by reducing space and operator which results in effectively utilization of space and the manpower. Different tools like takt time, line balancing, and MTM/UAS analysis are used to achieve the purpose. The integration of the 2 Lines is based on the LLD technique. [4] The expected benefit is to effectively utilize the space and manpower by 50% and 30%. A. Method time measurement (MTM) and universal analysis system (UAS) - is a Fig 2: Flow chart of LLD approaches Predetermined Time Systems used primarily in industrial settings to analyze 2177.

6 ISSN: 2278 1323. International Journal of Advanced Research in Computer Engineering & Technology (IJARCET). Volume 2, Issue 6, June 2013. II. Problem Statement B. Planned Cycle Time (PC/T) - It is the In recent days A elements has encountered Customer Takt Time taking into accounts with a fluctuation in demand , from high C. all influencing parameters and losses demand to moderate demand, and there is a (included in OEE) at maximum capacity moderate demand for B elements, therefore of the line. Equation to calculate CTT is there is no effective utilization of the line and as below in 2.

7 The man power in both the Pumps. 2: PC/T. III. Initial Calculation A. Customer Takt Time (CTT) - It is the rate Note: Planned cycle time need to be at least at which products or parts must be 10% less than CTT, so that the product produced to fulfill customer orders. could be delivered on time Equation to calculate CTT is as below in 1. The CTT and the PC/T for the A and B line is calculated as shown in the table 1. Which shows us how the CTT and PC/T for 1: CTT A and B line is done. Planned Operating Volume Working Demand per CTT PC/T. Time / day A days B day = A/B.

8 25200 seconds 9812 24 days 409 units 62 52. A. units Seconds Seconds 25200 seconds 840 24 days 35 units 720 612. B. units Seconds Seconds Table 1: CTT and PC/T calculation for A and B line IV. Asses Current Condition Current layout of A and B elements can be A. Current Layout referred to the fig 3 and 4 shows the current layout, where B line need to be accommodated into A line Fig 3: Existing layout of A' Assembly line Fig 4: Existing layout of B' Assembly line B. Process Flow Process flow would help us to know the flow carried out in the Assembly line. [1] The below fig 5 and fig 6 shows us the process flow currently carried out in A and B Lines respectively.

9 2178. ISSN: 2278 1323. International Journal of Advanced Research in Computer Engineering & Technology (IJARCET). Volume 2, Issue 6, June 2013. C. Work Distribution Diagram Manual Time Time studies of manual times and process In In times for each station/operator will be copied Line Station Type TMU Sec into the operator balance chart. The time A Station A2 MTM studies can be obtained by time study method A Station A7 UAS or method time measurement/ universal B Station B2 MTM analysis system (MTM/UAS) methods. B Station B3 UAS 1005 MTM Method (Method Time Table 2A: Example of MTM and UAS.)

10 Measurement) - Time determination MTM analysis basic method is a Predetermined Time Systems that is used primarily in industrial A In Seconds settings to analyze the methods used to perform any manual operations or task & as a Station Manual Auto product of that analysis, let the standard time Station A1 0. in which a worker should complete the task Station A2 0. UAS (Universal Analysis System) - Station A3 30 UAS is a procedure for dividing a manual task into so called basic procedures, which Station A4 0. consists of a combination of frequently Station A5 2. recurring basic sequences of motion.