Title: Process improvements using lean methodologies in a subassembly line

Authors: Roja Kondate; Shanthi Muthuswamy; Miguel Rojas-Santiago

Addresses: Department of Industrial and Systems Engineering, Northern Illinois University, De Kalb, Il-60115, USA ' Department of Engineering Technology, Northern Illinois University, De Kalb, Il-60115, USA ' Departamento de Ingeniería Industrial, Universidad del Norte, Barranquilla, Colombia

Abstract: This research study focused on an engine subassembly line at a manufacturing facility. The objective of the study is two-fold: 1) to reduce takt time for engine build by implementing continuous improvement methodologies using lean principles; 2) to minimise the risks this subassembly line is currently prone to because of area congestion, safety issues and ergonomic concerns. Takt time was reduced by 25% by improving the layout using kaizen events based on the input obtained from time studies and motion studies (with spaghetti maps and heat maps). Failure mode effect analysis and three-dimensional static strength prediction program software were used to study the safety risks and ergonomic issues respectively and recommendations were implemented to improve the current working environment.

Keywords: lean; kaizen event; failure mode effect analysis; FMEA; spaghetti diagram; motion study; time study; heat maps.

DOI: 10.1504/IJSSCA.2020.112355

International Journal of Six Sigma and Competitive Advantage, 2020 Vol.12 No.4, pp.313 - 326

Received: 31 Oct 2019
Accepted: 22 Apr 2020
Published online: 12 Jan 2021 *

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