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Improvement of Assembly Line Efficiency by Using Lean Manufacturing Tools and Line Balancing Techniques

Mortada Anass, Soulhi Aziz

Advances in Science and Technology. Research Journal

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2023

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Vol. 17, no 4

89--109

EN

This paper presents a solid methodology for improving the efficiency and productivity of assembly lines using Lean Manufacturing tools, in particular the Define, Measure, Analyze, Improve, and Control approach (DMAIC) and line balancing techniques, followed by a concrete application in a case study of a wiring industry assembly line. The first phase of the approach ensured a clear definition of the problem using the who, what, where, when, why, and how tool (5W1H) and a description of the manufacturing process. The measurement phase allowed the calculation of the Takt time (TT) and the timing of the cycle times of the 17 stations of the line with the use of data collected on the standardized work combination table (SWCT) documents. This facilitated the analysis phase by first establishing a Yamazumi chart showing the distribution of the load between the line's stations and allowing the identification of bottleneck stations, and then analyzing the situation through the 5-Why tools and the Ishikawa diagram. Thanks to the innovation phase and the ideal balancing conditions developed in this paper, it was possible to balance the line's stations using an action plan whose effectiveness was monitored during the control phase, improving efficiency from 78% to 95% with a saving in manpower by reducing the number of operators from 17 to 14.

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Optimization of production processes using the Yamazumi method

Sabadka D., Molnár V., Fedorko G., Jachowicz T.

Advances in Science and Technology. Research Journal

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2017

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Vol. 11, no 4

175--182

EN

Manufacturing companies are now placing great emphasis on competitiveness and looking for ways to utilise their resources more efficiently. This paper presents optimum efficiency improvement of the automotive transmission assembly production line by using line balancing. 3 assembly stations were selected to optimize where waste management requirements are not met for achieving the production capacity. Several measures were proposed on the assembly lines concerned to reduce operations by using eliminating unnecessary activities of the assembly processes, reducing the cycle time, and balancing manpower workload using line balancing through Yamazumi chart and Takt time. The results of the proposed measures were compared with the current situation in terms of increasing the efficiency of the production line.

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Lean tool used in the automotive industry

Ingaldi M., Jagusiak-Kocik M.

Production Engineering Archives

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2014

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Vol. 4, No. 3

7--10

EN

In the paper basic concepts of Lean Manufacturing were presented. A company specializing in the development of vehicle dynamics, driver assistance systems, brake systems, seat belt sand electronics technology was characterized. The company is engaged in designing and manufacturing world-class products for the automotive market. The Lean tools used in the production hall, such as Yamazumi chart, machine motion analysis, MTM method and timing, were presented.