Title: Improving performance of lock assembly line using lean and simulation approach

Authors: Arun Bhiva Rane; Vivek K. Sunnapwar; Narasimhan R. Chari; Mahesh R. Sharma; V.S. Jorapur

Addresses: Department of Production Engineering, Fr. C. Rodrigues College of Engineering, Bandra (W), Mumbai-400 050, India ' Lokmanya Tilak College of Engineering, Koparkhairane, Navi Mumbai-400 709, India ' D.J.Sanghavi College of Engineering, Vile Pale (w), Mumbai-400056, India ' Department of Information Technology; Department of Production Engineering, Fr. C. Rodrigues College of Engineering, Bandra (W), Mumbai-400 050, India ' Department of Information Technology and Department of Production Engineering, Fr. C. Rodrigues College of Engineering, Bandra (W), Mumbai-400 050, India

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.

Keywords: assembly line optimisation; discrete event simulation; DES; Arena; line balancing; lean production; mixed models; assembly line efficiency; performance evaluation; lock assembly; process modelling; performance improvement; cycle time; throughput; resource utilisation; cost reduction; layout; resource distribution; operations; time study; Maynard operation sequencing technique; MOST; kaizen; total productive maintenance; TPM; line balancing; low cost automation.

DOI: 10.1504/IJBPM.2017.080849

International Journal of Business Performance Management, 2017 Vol.18 No.1, pp.101 - 124

Received: 23 Jun 2015
Accepted: 22 Jan 2016
Published online: 09 Dec 2016 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article