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Production improvement on the assembly line through cycle time optimization

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Abstract

In this present work, the approach is for the adoption of virtual manufacturing in an assembly line system in which the assembly of Frame, Axle, Engine, Cab Body, and Trim is done over chassis in an automobile industry Trim Chassis and Frame shop. The major goal is to align the conveyor system's speed (Takt Time) and the Electrified Monorail Hoist System's speed with the conveyor system's speed. Various process parameter combinations are employed to achieve varied production rates while maintaining a smooth process flow among material handling equipment. Different volume levels were used to simulate the chassis assembly line. The system's efficiency was assessed using simulated data. By substituting manual processes with 3D simulation, Delmia Quest software aids in the detection of process planning flaws. The use of 3D simulation in the design of the process flow aids in the verification of equipment motion as well as the detection of crashing and trafficking on the assembly line system. CATIA® was used to design the assembly line, and Delmia QUEST was used to simulate it in real time. The proposed effort intends to provide a better understanding of assembly line production and the numerous manufacturing techniques and procedures that are necessary during the manufacturing process in order to reduce manufacturing costs and idle time while also increasing productivity. The operator loading improved by 8% after adding 313.92 min of new job content, while vehicle number increased by 5 vehicles each shift.

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Authors and Affiliations

  1. Department of Production and Industrial Engineering, NIT Jamshedpur, Jamshedpur, 831014, India

    Pankaj Kumar, Shashi Bhushan Prasad & Dharmendra Patel

  2. Rajdhani College, Delhi University, New Delhi, India

    Laxmi Gupta

  3. Manav Rachna University, Faridabad, India

    Manmeet Bali Nag & Priyanka Chadha

Authors
  1. Pankaj Kumar
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  2. Shashi Bhushan Prasad
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  3. Dharmendra Patel
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  4. Laxmi Gupta
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  5. Manmeet Bali Nag
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  6. Priyanka Chadha
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Correspondence to Pankaj Kumar.

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Kumar, P., Prasad, S.B., Patel, D. et al. Production improvement on the assembly line through cycle time optimization. Int J Interact Des Manuf 17, 2617–2630 (2023). https://doi.org/10.1007/s12008-022-01031-8

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  • DOI: https://doi.org/10.1007/s12008-022-01031-8

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