Int. J. of Industrial and Systems Engineering   »   2015 Vol.20, No.1

 

 

Title: Lean methodologies to improve assembly line efficiency: an industrial application

 

Authors: Kaneesa Kanaganayagam; Shanthi Muthuswamy; Purushothaman Damodaran

 

Addresses:
Department of Industrial and Systems Engineering, Northern Illinois University, De Kalb, Il 60115, USA
Department of Technology, Northern Illinois University, De Kalb, Il 60115, USA
Department of Industrial and Systems Engineering, Northern Illinois University, De Kalb, Il 60115, USA

 

Abstract: Similar to automobile industries, the large earth moving equipment (LEME) industries have a dominant assembly line layout. Improving the assembly line efficiency would improve the productivity of the line. This paper focuses on using lean tools such as time and motion study, kaizen events and spaghetti map to reduce waste in a LEME assembly line. For this research, five zones (or work areas) of assembly were studied and using the lean tools the cycle time was reduced to achieve a 15% reduction in takt time. There were four phases to this research effort: data collection, construction of the process flow map, creation of the spaghetti map, and the implementation of kaizen events. The results from this research demonstrate that waste in an assembly can be identified and removed by studying the process and utilising simple yet powerful lean tools.

 

Keywords: lean manufacturing; time and motion study; kaizen events; spaghetti diagram; assembly line efficiency; large earth moving equipment; LEME industry; assembly productivity; takt time; data collection; process flow mapping; waste identification; waste removal.

 

DOI: 10.1504/IJISE.2015.069000

 

Int. J. of Industrial and Systems Engineering, 2015 Vol.20, No.1, pp.104 - 116

 

Available online: 24 Apr 2015

 

 

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