Title: Mathematical modelling of vehicle assembly line for throughput enhancement

Authors: Arun Bhiva Rane; Vivek K. Sunnapwar; S.M. Khot; Ramesh Vulavala

Addresses: Department of Production Engineering, Fr. C. Rodrigues College of Engineering, Bandra (W), Mumbai-400 050, India ' Lokmanya Tilak College of Engineering, Koparkhairane, Navi Mumbai-400 709, India ' Fr. C. Rodriguues Institute of Technology, Vashi, Navi Mumbai-400703, India ' D.J. Sanghavi College of Engineering, Vile Pale (w), Mumbai-400056, India

Abstract: The objective of this work is to improve the performance of vehicle assembly line by developing suitable mathematical relations between various influencing parameters affecting throughput. This work also systematically identifies and describes different approaches adopted by various research scholars through systematic review of peer-reviewed papers from reputable journals. There are several uncertainties in manufacturing environments. Here, mathematical models are developed to consider the impact of important influencing factors like equipment failure, short supply of material, absenteeism, set-up, material handling, rejection and fatigue on throughput. Then, inter-relationships are established between these parameters. Relationships between these parameters and their corresponding cost are also developed. Relationships are established scientifically using regression modelling, MATLAB, Minitab, Excel, Arena and discussions with domain experts. These are validated with real world data. Practitioners may use these models to predict and control uncertainty. Further, within a given cost constraint and using lean techniques, cycle time may be reduced.

Keywords: simulation; optimisation; lean manufacturing; mathematical modelling; assembly line balancing; throughput; utilisation; efficiency; cost constraints; downtime added; vehicle assembly lines; uncertainty control; equipment failure; material shortages; absenteeism; set-up; materials handling; rejection; fatigue.

DOI: 10.1504/IJSPM.2016.078511

International Journal of Simulation and Process Modelling, 2016 Vol.11 No.3/4, pp.305 - 325

Available online: 19 Aug 2016 *

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