International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025
p-ISSN: 2395-0072
www.irjet.net
Improvement in Construction Equipment Assembly Line Using Industrial Engineering Techniques Dr. R Jayachitra1, Balaji G K2, Sudharsan C3 1Associate Professor, Department of Mechanical Engineering, PSG College of Technology, Coimbatore, India 2Department of Mechanical Engineering, PSG College of Technology, Coimbatore, India
3Department of Mechanical Engineering, PSG College of Technology, Coimbatore, India ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - The integration of new product lines into existing
operations is a critical challenge. This calls for sophisticated planning and robust process control mechanisms. Industrial engineering provides a proven framework for achieving these objectives through data-driven analysis, workflow optimization, and implementation of lean principles.
manufacturing systems presents complex operational challenges, particularly in mixed-model assembly line environments. This study explores a comprehensive improvement initiative undertaken at a construction equipment manufacturing company, a leading Indian manufacturer of construction equipment, aimed at integrating a new model—SKT—into its existing assembly line. Initial assessments revealed a high Defects Per Machine (DPM) rate of 424, along with systemic inefficiencies in documentation, facilities and quality control. The project employed a suite of industrial engineering methodologies and FlexSim-based simulation modeling. Data were collected across multiple stages of assembly, and the process flow was analyzed to identify bottlenecks and Non-Value-Added (NVA) activities. Corrective and Preventive Action (CAPA) measures were implemented to address key defect areas. Projectile study was performed to calculate the average NVA percentage of the assembly line. Simulation results post-intervention demonstrated a nullification in DPM, takt time alignment, and current process throughput. The study concludes by providing facilities and Standard Operating Procedure (SOP), leads to cycle time reduction by 14.2%, states that engineering tools can significantly enhance efficiency, product quality, and readiness for new product integration in complex manufacturing settings.
Despite company’s advanced manufacturing capabilities, the pilot run of SKT resulted in a DPM count of 424— significantly higher than industry-acceptable benchmarks. This high defect rate not only threatened product quality but also indicated systemic issues such as lack of standardized work procedures, insufficient operator training, and inadequate layout planning. Given these conditions, a comprehensive improvement project was initiated with the following goals:
Nullifying the DPM count from the current level
Ensure defect-free integration of SKT into the existing line,
Optimize workflow and cycle time without additional capital expenditure.
Provide facilities and the proper documentation for the integration.
Key Words: Mixed-model assembly line, Lean, Simulation, Non-Value-Added (NVA) activities, Corrective and Preventive Action, New product integration
This paper details the structured methodology, analysis, implementation, and outcomes of the project, demonstrating how the application of industrial engineering principles can revitalize assembly operations and enable seamless product innovation.
1.INTRODUCTION
2.LITERATURE REVIEW
Indian manufacturing sector, particularly the construction equipment segment, has been evolving rapidly to meet domestic and international market demands. As part of a strategic initiative to expand its product portfolio, the company introduced a new model called SKT. Unlike legacy models, SKT required customized assembly processes due to its unique configuration and design considerations.
The reviewed literature collectively emphasizes the importance of productivity enhancement, defect reduction, and assembly line optimization within manufacturing environments. Several studies have explored lean manufacturing principles. The summary of the previous research papers with their objectives, Approach and outcomes are summarized as shown in Table 1.
In high-mix, low-volume production settings such as construction equipment manufacturing, the integration of new products into existing lines without disrupting ongoing
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