Productivity Improvement of an Assembly Line through Line Balancing and Yamazumi: A Case Study of Cummins Turbo Technologies, Dewas

Abstract

Improvement of productivity in terms of man-machine material method money has become a buzzword nowadays. Every organization is working for maximising the use of resources. There are so many methods and lean tools to improve the productivity of an assembly line. Lean has worked on so many problems to improvise the productivity of an assembly line.
This project is based on applying proper workload balancing on the workstations of a turbocharger assembly line in an automobile manufacturing company by restructuring the workload within the assembly line.
This paper presents the method to solve the assembly line balancing problem. Assembly line station number 6 has a cycle time of 109 sec which is 40% more than of next bottleneck station and has adversely impacted the productivity and workload balancing of the assembly line. The main focus of the paper is to improve the overall efficiency of the assembly line by a distribution of equal workload in each workstation. In which first we need to calculate the cycle time of the process and identify the bottleneck and calculate the total work content and distributing equally to all the stations. This improved productivity of an assembly line from 190/shift to 300/shift i.e. 58% productivity improvement.