Title: Assembly line conversion approach: a simulation evaluation

Authors: Shahrul Kamaruddin; Kok-Wui Boon; Zahid Akhtar Khan; Arshad Noor Siddiquee

Addresses: School of Mechanical Engineering, Universiti Sains Malaysia Engineering Campus, Nibong Tebal, 14300, Penang, Malaysia. ' School of Mechanical Engineering, Universiti Sains Malaysia Engineering Campus, Nibong Tebal, 14300, Penang, Malaysia. ' Department of Mechanical Engineering, Faculty of Engineering & Technology, Jamia Millia Islamia, Central University, Jamia Nagar, New Delhi 110025, India. ' Department of Mechanical Engineering, Faculty of Engineering & Technology, Jamia Millia Islamia, Central University, Jamia Nagar, New Delhi 110025, India

Abstract: Flow line layout has the characteristics of meeting high volume with low product variety production. However, the market trend nowadays focuses on customisation where product orders come in small batches but with high product variety. Therefore, cellular layout becomes a preferable type of layout due to its ability to cope with low volume and high product variety. The conversion of flow line to cellular layout is focused in this study and assembly line conversion approach is suggested as a guideline on designing the basic structure of cellular layout. The conversion will adopt lean concept on the manufacturing line. The converted layout will be further tested for its performance by using simulation modelling. Then, the behaviours of cellular layout are described and performance measures that show significant effect on the layout are reviewed by using analysis of variance (ANOVA).

Keywords: cellular layouts; lean concepts; analysis of variance; ANOVA; assembly lines; conversion approaches; simulation evaluations; flow lines; product variety; high volumes; low variety; market trends; customisation; product orders; small batches; high variety; low volumes; manufacturing lines; converted layouts; simulation modelling; performance measures; agile systems; agile management.

DOI: 10.1504/IJASM.2011.043131

International Journal of Agile Systems and Management, 2011 Vol.4 No.4, pp.342 - 363

Received: 22 Oct 2010
Accepted: 18 Mar 2011

Published online: 17 Oct 2011 *

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