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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

2023

Vol. 17, no 4

89--109

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.

Applications Use Standardized Work Purpose of Increase the Production Capacity – a Case Study

Rewers P., Mandziuk M, Trojanowska J.

Research in Logistics & Production

2015

Vol. 5, No. 2

191--200

The article presents the results of research carried out in the company of the foundry industry. Actions taken in the company were to analyze the losses occurring at selected positions and the implementation of standardized work procedures to improving the production process. Describes the state of the current position and manner of operations by the employee, taking into account the distances driven during the execution of the various treatments. The article presents the objectives of the program TWI (Training Within Industry), with special emphasis of the program on the improvement of working methods (MP). The proposed solutions are designed to improve working conditions in the enterprise, and shortening the distances that overcomes the operator also contributes to increased safety. The main effect introduced in the enterprise improvement activities is to increase employee productivity by reducing the execution time of repeated treatments with the introduction of standardized work rules.