Wyniki wyszukiwania - BazTech

1

Productivity Improvement Based on the Theory of Constraint and Eliminate, Combine, Rearrange, Simplify for Chilled Beef Production in Indonesia

Neisyafitri Rendayu Jonda, Ongkunaruk Pornthipa, Ongcunaruk Wisute

Management and Production Engineering Review

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2023

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Vol. 14, No. 2

111--123

EN

This paper aims to enhance the productivity of a chilled beef production line by comparing two techniques; standard time calculation and simulation. The best improvement method was obtained using the work-study principle, a network diagram, and bottleneck identification. Two methods for improvement are proposed based on the ECRS, the Theory of Constraint (TOC), and line balancing concepts. A simulation model is developed to mimic the actual production line. The simulation results are verified, validated, and compared. Some workstations were combined, and the allocation of the workers was arranged. The present production line efficiency was 46.21%, which increased to 67.09% and 79.71% from the suggested methods. It showed that using the standard time calculation gives a different result from the simulation. In summary, the simulation model along with the application of TOC and ECRS, provides accurate information and improves overall productivity.

2

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.

3

Improving the Apparel Production Process by Using Simulation Modelling with a Waves Algorithm

Ünal Can, Kaya Ayşegül, Erdoğan Medine, Güngör Ayhan

Fibres & Textiles in Eastern Europe

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2021

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Vol. 29, no. 4 (148)

32--38

EN

In this study, a simulation study was carried out in order to increase the production efficiency of a company that produces hoodies. The simulation technique has been included in many studies for line balancing in the apparel industry. However, in this study, unlike others, an algorithm that can be easily applied is proposed for the software practitioner to use in the alternative model development process in order to increase the efficiency of an existing production line. Based on real production line data, a waves algorithm was applied in the simulation model, whose verification and validity processes were completed. In the results obtained with the help of the waves algorithm (acting according to two different assignment scenarios), it was determined that the average production values per person had increased.

PL

W pracy przeprowadzono badanie symulacyjne w celu zwiększenia wydajności produkcyjnej firmy produkującej bluzy z kapturem. Technika symulacji została uwzględniona w wielu badaniach dotyczących wyważania linii w przemyśle odzieżowym. Jednak w tym badaniu, w przeciwieństwie do innych, zaproponowano algorytm, który może być łatwo zastosowany w praktyce. Na podstawie rzeczywistych danych linii produkcyjnej w modelu symulacyjnym zastosowano algorytm falowy. Po analizie wyników uzyskanych za pomocą algorytmu falowego (działającego według dwóch różnych scenariuszy przydziału) stwierdzono wzrost średnich wartości produkcji na osobę.

4

Simulation for jewelry production process improvement using line balancing: A case study

Supsomboon Srisawat

Management Systems in Production Engineering

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2019

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nr 3 (27)

127--137

EN

Thai jewelry is the world’s leading jewelry which has gained high reputation and recognition from customers worldwide. In the past decade, jewelry have become one of the top ten export product of Thailand with the current export value of around 58,000 million baht per year which is 3.4 percent of all Thailand export products. Due to the high competition in the world market, however, Thai jewelry manufacturers needs to continue to improve their product quality as well as process efficiency in order to gain more market share. Currently, computer-aided tools have become more powerful tool in jewelry production management. They have been used to design production process, plant and workstation layout, production planning, worker’s scheduling, and other decisive decision making in both high management and shop floor levels. This research demonstrates a case study of plant simulation application for jewelry production process improvement. The objective is to reduce bottlenecks and increase productivity in wax pattern and casting processes using line balancing. Various scenarios have been proposed in order to support different level of desired output rate due to the increase of demand. The results of line balancing and simulation models reduce bottlenecks. Hence, productivity is increased. The desired throughput rates are achieved with the minimum number of workers and machine in the system.

5

Lean Tool Implementation in the Garment Industry

Kumar D. Vasanth, Mohan G. Madhan, Mohanasundaram K. M.

Fibres & Textiles in Eastern Europe

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2019

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Vol. 27, no. 2 (134)

19--23

EN

Garment Manufacturing is one of the oldest in the world, compromising a high number of critical operations. The main issues in the garment industry are the lead time, production rate, very poor line balancing and fabric wastes. Productivity improvement is carried out by implementing the various lean tools in the industry, such as 5S, Value Stream Mapping (VSM) and line balancing in the sewing section. After the implementation of lean tools in the garment industry, the outcomes observed are a reduction in work-in-progress inventory, increases in the production process and increased line efficiency. Similarly the before and after implementation of 5S, which shows space utilisation in the sewing section, is increased. In this research, an implementation study was conducted in only one organisation. Hence the results extracted by the conduct of this implementation study are achievable and adaptable in similar organisations.

PL

Główne problemy w przemyśle odzieżowym to czas realizacji, tempo produkcji, bardzo niska równowaga linii i marnotrawstwo tkanin. Celem pracy było uzyskanie poprawy produktywności poprzez wdrożenie różnych narzędzi „Lean Management” w branży, takich jak 5S, Mapowanie Strumienia Wartości (VSM) i równoważenie linii w dziale szycia. Po wdrożeniu narzędzi „Lean Management” w przemyśle odzieżowym na podstawie uzyskanych rezultatów zaobserwowano zmniejszenie zapasów w toku prac, zwiększenie procesu produkcji i zwiększenie wydajności linii. Przedstawione w pracy wyniki dotyczą badania wdrożeniowego przeprowadzonego w jednej organizacji. W związku z tym wyniki uzyskane w ramach tego badania są możliwe do osiągnięcia i dostosowania w podobnych organizacjach.

6

Creating an Alternative Production Line by Using a Simulation Technique in Duvet Cover Production

Ünal C., Demirbaş Z. A.

Fibres & Textiles in Eastern Europe

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2018

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Vol. 26, no. 4 (130)

8--12

EN

In this study, the discrete-event system simulation technique was used in order to create smooth work flow on a duvet cover production line. In accordance with this purpose, a model of the work flow of a duvet cover was created, and input data was collected by means of a time study in order to determine the statistical distribution of all operations using Stat-fit for Simul8 software. The model translation phase was executed in Simul8 Software. Then for the purpose of the verification and validation process, actual system data and simulation model outputs were compared statistically using the normality test and Mann-Whitney non-parametric test in Minitab Software. Once the simulation model of the actual system was properly validated, an alternative model considering fewer operators was generated in order to acquire more output and have a smoother line balance. The alternative model was compared with main one by considering the output rate per operator.

PL

W pracy zastosowano technikę symulacji dyskretnych zdarzeń w celu uzyskania płynnego przepływu pracy na linii produkcyjnej poszewek na kołdry. Stworzono model przepływu pracy, a dane wejściowe zebrano za pomocą analizy czasu w celu określenia rozkładu statystycznego wszystkich operacji przy użyciu Stat-fit dla oprogramowania Simul8. Faza translacji modelu została wykonana w oprogramowaniu Simul8. Następnie dla celów procesu weryfikacji i walidacji, rzeczywiste dane systemowe i wyniki modelu symulacyjnego porównano statystycznie za pomocą testu normalności i nieparametrycznego testu Manna-Whitneya w oprogramowaniu Minitab. Aby uzyskać większą wydajność i uzyskać bardziej płynny bilans linii po prawidłowym sprawdzeniu modelu symulacyjnego rzeczywistego systemu wygenerowano alternatywny model uwzględniający mniejszą liczbę operatorów. Model alternatywny porównano z głównym, biorąc pod uwagę wielkość produkcji na operatora.

7

Multi-objective approach for production line equipment selection

Chehade H., Dolgui A., Dugardin F., Makdessian L., Yalaoui F.

Management and Production Engineering Review

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2012

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Vol. 3, No. 1

4-17

EN

A novel problem dealing with design of reconfigurable automated machining lines is considered. Such lines are composed of workstations disposed sequentially. Each workstation needs the most suitable equipment. Each available piece of equipment is characterized by its cost, can perform a set of operations and requires skills of a given level for its maintenance. A multiobjective approach is proposed to assign tasks, choose and allocate pieces of equipment to workstations taking into account all the problem parameters and constraints. The techniques developed are based on a genetic algorithm of type NSGA-II. The NSGA-II suggested is also combined with a local search. These two genetic algorithms (with and without local search) are tested for several line examples and for two versions of the considered problem: bi-objective and four-objective cases. The results of numerical tests are reported. What is the most interesting is that the assessment of these algorithms is accomplished by using three measuring criteria: the direct measures of gaps, the measures proposed by Zitzler and Thiele in 1999 and the distances suggested by Riise in 2002.

8

Line Balancing in the Apparel Industry Using Simulation Techniques

Güner M. G., Ünal C.

Fibres & Textiles in Eastern Europe

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2008

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Vol. 16, no. 2 (67)

75--78

EN

Line balancing problems are well-known applications of industrial engineering departments. Different kinds of line balancing algorithms have been applied for many years in the apparel industry. However manual-operations oriented system of this sector makes it impossible to gain certain results with the algorithms currently used, and also makes it difficult to predict upcoming events when the production system is modified. This paper investigates and demonstrates the application of computer simulation for the design of a manufacturing process for t-shirt production in a virtual-reality environment. For this purpose, lots of data are collected from the real system and alternative systems are composed in order to find best one.

PL

Różnego rodzaju algorytmy są od wielu lat stosowane dla bilansowania taśm produkcyjnych w przemyśle odzieżowym. Jednak struktura produkcji w tym przemyśle zdominowana przez operacje manualne uniemożliwia uzyskanie satysfakcjonujących rezultatów przy stosowaniu obecnie używanych algorytmów i utrudnia przewidywanie zdarzeń przy modyfikacji systemu produkcji. W artykule przeanalizowano zastosowanie symulacji dla zaprojektowania procesu produkcji t-shirt’ów w wirtualnym środowisku. W tym celu zgromadzono zestawy danych z rzeczywistych systemów produkcyjnych i zaprojektowano alternatywne systemy w celu wybory najbardziej korzystnych rozwiązań

9

Developing and deploying electronics assembly line optimization tools: a Motorola case study

Tirpak T. M.

Decision Making in Manufacturing and Services

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2008

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Vol. 2, no. 1-2

63-78

EN

The assignment of workloads to production equipment is one category of planning decision for an electronics assembly factory. In practice, line balancing requires not only selecting machines with sufficient placement accuracy and feeder capacity, but also addressing a host of other operational objectives and constraints. Motorola Labs led a multi-year effort to apply mathematical programming to balance a variety of production mix and volume scenarios. By representing the optimization problem as a specially structured, mixed linear-integer program, we were able to incorporate a high degree of reality in the model, simultaneously optimizing fixed setups, handling custom parts, maximizing machine uptime, and mitigating secondary bottlenecks. This paper presents the story of how we developed and deployed a software solution that significantly improved assembly cycle times, setup changeovers, and overall factory productivity, saving the company tens of millions of dollars.

10

A transfer line balancing problem by heuristic methods: industrial case studies

Guschinskaya O., Dolgui A.

Decision Making in Manufacturing and Services

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2008

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Vol. 2, no. 1-2

33-46

EN

The paper deals with the problem of optimal configuration of a type of transfer lines which are equipped with transfer machines. Such machines perform operations with standard modular spindle heads which are activated sequentially. All operations assigned to the same spindle head (block of operations) are executed simultaneously by a set of tools fixed at the spindle head. The quantity of machines and spindle heads used to produce a part with the given productivity rate defines the final cost of the transfer line which must be minimized. To minimize this cost, a combinatorial problem of operations assignment to blocks and machines must be solved. The solution must provide a desired productivity (cycle time), it must also satisfy precedence and compatibility constraints. In this paper, we suggest improved versions of FSIC heuristic algorithm in order to help line designers to solve real-scale industrial problems. Results of computational experiments obtained for industrial cases are presented.