International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue:10 | Oct 2024
p-ISSN: 2395-0072
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ROOF RAIL ASSEMBLY CELL PRODUCTIVITY ENHANCEMENT VIA TIME STUDY ANALYSIS Rishya Shringhan Ravichandran ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - The principal objective in manufacturing
fundamental metric in organizational performance and operational efficiency.
operations is maximizing output with minimal workforce exertion, ensuring to achieve the desired product and target quality. In manufacturing, the optimization of operation efficiency and productivity of a product is a prevailing issue. To enhance the productivity among several manufacturing units, the motion and time study strategy is employed. This technique is used to determine the most efficient approach for executing repetitive tasks and to accurately measure the time required by an average operator to complete a task within a standardized work environment. In every manufacturing industry, optimizing assembly line configurations is important for productivity augmentation. The objective of this paper is to analyze the implementation of motion critically and time study methodologies on 2-station and 3-station assembly lines and their effects on productivity enhancement. The pre-and post-application of motion and time study techniques have been assessed, presenting a detailed comparison of process outcomes. The findings reveal a remarkable 30.86 % increase in average productivity. Thus, it can be inferred that time study serves as an effective tool for enhancing productivity in manufacturing processes.
F.W. Taylor [1], the progenitor of modern time and motion study methodologies, commenced his time study research in 1881. Despite facing significant criticism initially, the technique has progressively gained widespread acceptance as a fundamental method for work measurement in technical contexts. Womack et al. (1990) [2] extrapolated from the highly efficacious Toyota Production System, emphasizing the systematic eradication of all forms of waste to optimize operational efficiency. Krafcik (1998) [3] elucidates the Japanese manufacturing paradigm championed by Toyota, characterized by a spectrum of methodologies such as Just-In-Time (JIT) inventory systems, Kaizen-driven continuous improvement, and the implementation of quality circles. Niebel (1988) [4] posits that the exclusive method for a business or enterprise to attain growth and amplify profitability is through the enhancement of productivity across all operational dimensions, including sales, finance, production, engineering, cost management, maintenance, and organizational administration.
Key Words: Productivity Enhancement, Motion and Time Study, Operation Efficiency, Manufacturing Operations
Imad Alsyouf (2007) [5] demonstrated the impact of a robust maintenance policy on the productivity and profitability of manufacturing processes. Additionally, the study highlighted the influence of productivity changes on profitability, distinct from the effects of uncontrolled factors such as price recovery. As per Atkinson et al. (1995) [6], productivity is quantified as the ratio of the monetary value of outputs (produced goods or services) to the monetary value of input resources (including wages, equipment costs,) and similar expenditures utilized in the production process.
1. INTRODUCTION Assembly lines are well-planned production systems designed to accommodate the increase in demands of society. The growing demand for product diversity and shorter product life cycles has led to the replacement of traditional manufacturing methods with well-designed assembly lines. The goal of the system is to achieve highvolume production at accelerated rates, optimize efficiency, and ensure a guarantee of stringent quality guidelines.
S. Vijaya Kumar et al. [7] undertook a study to optimize production planning and process efficiency at an impeller manufacturing facility. The goal was to minimize CNC machining time for impellers, and vital components in centrifugal pumps, employing Overall Equipment Effectiveness (OEE) strategies. Additionally, the author implemented quick changeover techniques to streamline setup times for standardized products using the OEE methodology. The outcome demonstrated a 4.4% performance boost and a significant 47% reduction in setup times for certain impeller types.
An assembly line is an array of workstations that are sequenced strategically along a conveyor mechanism. Each workstation is assigned specific operations within predefined constraints. The bottleneck is the cycle time, defining the time span between the two finished units or the maximum allowed time for fabricating any workpiece at a designated workstation. The effectiveness of product or service efficacy is typically determined through detailed time studies, adherence to time standards, utilization of work sampling methods, and analysis of operator’s feedback. These methodologies highlight the importance of time as a
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