Zlepšení výrobní linky motorů

Abstract

In company XYZ, numerous products are manufactured. More specifically, for the vehicle, different kinds of wiper motors are manufactured according to customer needs. In the assembly, there are five lines namely Stator, Rotor, Pivot housing, Motor, and Wiper line. Every Motor line is divided into segments. Every segment consists of many workstations. Each workstation consists of many processes. Each segment has its own bottleneck and also takt time. Each workstation has its own cycle time. The current layout used in the Motor line is I shaped layout (I-type layout). Since the length of the line is too long, it creates more trafficking of materials in line thereby resulting in the decrement of production efficiency. Hence, a new type of layout is proposed which is U shaped layout (U-type layout) for preventing the trafficking of materials. The proposed line is designed and implemented not only for avoiding material traffic and better operator ergonomics but also for single piece flow which is the prevention of building up of stacks of inventory between the process steps in workstations. The production line efficiency is calculated for both layout and is compared to observe the increment in production efficiency of U type layout. Also, individual operator efficiency has been calculated for both layout and compared. For further improvement in production, KAIZEN (continuous improvement) has been proposed and implemented in the line for some workstations with the help of Group leader and team member.

In company XYZ, numerous products are manufactured. More specifically, for the vehicle, different kinds of wiper motors are manufactured according to customer needs. In the assembly, there are five lines namely Stator, Rotor, Pivot housing, Motor, and Wiper line. Every Motor line is divided into segments. Every segment consists of many workstations. Each workstation consists of many processes. Each segment has its own bottleneck and also takt time. Each workstation has its own cycle time. The current layout used in the Motor line is I shaped layout (I-type layout). Since the length of the line is too long, it creates more trafficking of materials in line thereby resulting in the decrement of production efficiency. Hence, a new type of layout is proposed which is U shaped layout (U-type layout) for preventing the trafficking of materials. The proposed line is designed and implemented not only for avoiding material traffic and better operator ergonomics but also for single piece flow which is the prevention of building up of stacks of inventory between the process steps in workstations. The production line efficiency is calculated for both layout and is compared to observe the increment in production efficiency of U type layout. Also, individual operator efficiency has been calculated for both layout and compared. For further improvement in production, KAIZEN (continuous improvement) has been proposed and implemented in the line for some workstations with the help of Group leader and team member.