Manufacturing Technology Today

B. Vijaya Ramnath ¹, C. Elanchezhian ¹, R. Kesavan ¹

Affiliations
1 Dept. of Production Technology, M.I.T. Campus, Anna University, Chrompet, Chennai, IN

Abstract

In order to sustain in present competitive market, on-time delivery, excellent quality and aesthetic are very much essential. The objective of this paper is reducing the cycle time of assembly of automobile door trim panels by implementing various modernized techniques using lean manufacturing concepts. It is evident from the past reports that in the existing system the cycle time is more and it has poor aesthetic. Here a leading automobile company's front door panel assembly is considered and the assembly line is modernized and automated to reduce the cycle time and to improve the aesthetic. The outcome of this paper leads to substantial reduction in cycle time, reduced cost of maintenance, reduced defects, better utilization of machines and man power. Statistical quality control is carried out on the new method of welding joints. The result shows that the process is under control. Also, the proposed system is validated for its increased productivity and for return on investment (ROI). It has been proved and validated by an empirical relation. The improved return on investment (ROI) and productivity shows the method of performing welding is feasible.

Keywords

Lean Manufacturing, Cycle Time Reduction, Return on Investment, Productivity.

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B. Vijaya Ramnath ¹, C. Elanchezhian ¹, R. Kesavan ¹

Affiliations
1 Dept. of Prod. Technology, M.l.T.Campus, Anna University, Chrompet, Chennai, IN

Abstract

The purpose of this paper is to develop an operationalized model, which can be used to access the changes taking place in an effort to introduce lean manufacturing system. We limited ourselves to the factors that concern the work organization in the manufacturing part of the company in order to develop an operational model of lean production. To bring the single piece flow assembly system, we have applied the principles of ergonomics, plant layout, and time study in this paper. These different principles have been elaborated using available theory behind the lean production system. The production system concept of process flow, plant layout, material flow, ergonomics and work place organization were integrated as a whole system in the plant. With the adaptation of above stated concepts, the assembly line became lean and also the productivity of the assembly line is comparably increased with the existing assembly system by 167%.

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