Process Improvements Using Lean Methodologies in a Subassembly Line

Publication Title

International Journal of Six Sigma and Competitive Advantage

ISSN

14792494

E-ISSN

14792753

Document Type

Article

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.

First Page

313

Last Page

326

Publication Date

1-1-2020

DOI

10.1504/IJSSCA.2020.112355

Keywords

Failure mode effect analysis, FMEA, Heat maps, Kaizen event, Lean, Motion study, Spaghetti diagram, Time study

Department

Department of Industrial and Systems Engineering; Department of Engineering Technology

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