Simulation analysis for assembly line workstation layout: case study

Intan Bazliah Mohd

Abstract


The paper explores the cost saving projects that have been implemented in an electrical product assembly line, so called subwoofer speaker. Observation has been conducted on 26 workstations which are involved in an assembly line. Group discussion, real time study and simulation analysis have been performed to reduce operational cost. The result shows that the proposed layout was improved at least 22.68% space utilisation in the production area but only able to improve at least 0.56 percent of production rate. The simulation result gave the production personnel to decide the best improvement workstation layout and enhance the participation of employee in cost saving activities while improve production capacity.

Full Text:

PDF

References


J. Ashayeri and L. Lemmes, “Economic value added of supply chain demand planning: a system dynamics simulation”, Robotic and Computer Integrated Manufacturing, vol. 22, pp. 550 – 556, 2006.

G. Reiner and M. Trcka, “Customised supply chain design: problems and alternatives for a production company in the food industry: a simulation based analysis”, International Journal of Production Economics, vol. 89, pp. 217 – 229, 2004.

M. Er and B. MacCarthy, “Managing product variety in multinational corporation supply chain: a simulation study”, Journal of Manufacturing Technology Management, vol. 17, no. 8, pp. 1117 – 1138, 2006.

L.J. Krajewski and L.P. Ritzman, Operation Management Strategy and Analysis: Fifth Edition, Addison Wesley Publishing: United States of America, 1999.

W.H.W. Mahmood, M.N.A. Rahman, B.M. Deros, K. Jusoff, A. Saptari, Z. Ebrahim, A.A.M. Sultan, M.H.A. Bakar, Sivarao and Z. Jano, “Manufacturing performance in greening supply chain management, special issue of engineering and technology, WASJ, vol. 21. pp.76-84, 2013.

M.Z. Yusup, W.H.W. Mahmood, M.R. Salleh, M.R. Muhamad and A. Saptari, “Synthesizing the domain of lean practices in manufacturing operations: a review”, Jurnal Teknologi, vol. 77, no. 1, pp. 153–162. 2015.

E. Fleisch and C. Tellkamp, “Inventory inaccuracy and supply chain performance: a simulation study of a retail supply chain”, International Journal of Production Economics, vol. 95, pp. 373 – 385, 2005.

J. Tannock, B. Cao, R. Farr and M. Byrne, “Data-driven simulation of the supply chain –insights from the aerospace sector”, International Journal of Production Economics, vol. 110, pp. 70-84, 2007.

F. Persson, and J. Olhager, “Performance simulation of supply chain designs”, International Journal of Production Economics, vol. 77, pp. 231 – 245, 2002.

J. O’Kane, “Simulating production performance: cross case analysis and policy implications”, Industrial Management & Data Systems, vol. 4, pp. 309 – 321, 2004.

S. Kumar and P. Phrommathed, “Improving a manufacturing process by mapping and simulation of critical operations”, Journal of Manufacturing Technology Management, vol. 17, no. 1, pp. 104 – 132, 2006.

M. Ozbayrak, T.C. Papadopoulou and M. Akgun, “System dynamics modeling of a manufacturing supply chain system”, Simulation Modeling Practice and Theory, vol. 15, pp. 1338 – 1355, 2007.

S. Rajakumar, V.P. Arunachalam and Selladurai, “Simulation of workflow balancing in assembly shop-floor operations”, Journal of Manufacturing Technology Management, vol. 16, no. 3, pp. 265 – 281, 2005.

A. Greasley, “The case for the organizational use of simulation”, Journal of Manufacturing Technology Management, vol. 15, no. 7, pp. 560 – 566, 2004.

Wassim Masmoudi, Hedi Chtourou and Aref Y. Maalej. “A simulation-expert-system-based approach for machine sizing of production systems”, Journal of Manufacturing Technology Management, vol. 17, no. 2, pp. 187 – 198, 2006.

B. Das, J.M. Sanchez-Rivas, A. Garcia-Diaz and C.A. MacDonald, “A computer simulation approach to evaluating assembly line balancing with variable operation times”, Journal of Manufacturing Technology Management, vol. 21, no. 7, pp. 872 – 887, 2010.

S-M., Aghazadeh, S. Hafeznezami, L. Najjar and Z. Huq, “The influence of work‐cells and facility layout on the manufacturing efficiency”, Journal of Facilities Management, vol. 9 no. 3, pp.213-224, 2011.

M.T. Gonçalves and K. Salonitis, “Lean assessment tool for workstation design of assembly lines”, Procedia CIRP, vol. 60, pp. 386-391, 2017.

F. Aqlan, S.S. Lam and S. Ramakrishnan, “An integrated simulation–optimization study for consolidating production lines in a configure-to-order production environment”, International Journal of Production Economics, vol. 148, pp. 51-61, 2014.

Mashitah Mohamed Esa, Nor Azian Abdul Rahman and Maizurah Jamaludin, “Reducing high setup time in assembly line: a case study of automotive manufacturing company in malaysia”, Procedia - Social and Behavioral Sciences, vol. 211, pp 215-220, 2015.

T. Koltai, N. Kalló and R. Györkös, “Calculation of the throughput-time in simple assembly lines with learning effect”, IFAC-PapersOnLine, vol. 48no. 3, pp. 314-319, 2015.

K. Shigematsu, Y. Yamazaki, S. Kato, F. Kojima and S. Takata, “Process-independent workstation layout for lean automation”, CIRP Annals, vol. 67, no. 1, pp. 475-478, 2018.

S. Kang and J. Chae, “Harmony search for the layout design of an unequal area facility”, Expert Systems with Applications, vol. 79, pp. 269-281, 2017.

A. Asef-Vaziri and M. Kazemi, “Covering and connectivity constraints in loop-based formulation of material flow network design in facility layout, European Journal of Operational Research, vol. 264, no. 3, pp. 1033-1044, 2018.

A.C., Caputo, P.M., Pelagagge, M. Palumbo and P. Salini, “Safety-based process plant layout using genetic algorithm”, Journal of Loss Prevention in the Process Industries, vol. 34, pp. 139-150, 2015.

R.A. Gerald, R.O. John and J.S Marc, “U-shaped assembly line layouts and their impact on labour productivity: an experimental study”, European Journal of Operational Research, vol. 156, pp. 698-711, 2004.

F. Mirko, B. Simon, K. Simon, B. Joze, B. Miran, and P. Ivo, “Intelligent design of an unconstrained layout for a flexible manufacturing system”, Neurocomputing, vol. 73, pp. 639-647, 2010.

B.A. Kotzur, R.J. Berry, S. Zigan, P. García-Triñanes and M.S.A. Bradley, “Particle attrition mechanisms, their characterisation, and application to horizontal lean phase pneumatic conveying systems: A review”, Powder Technology, vol. 334, pp. 76-105, 2018.

T. Bortolotti, S. Boscari and P. Danese, “Successful lean implementation: organizational culture and soft lean practices”, International Journal of Production Economics, vol. 160, pp. 182 – 201, 2015.

Z. Wei, X. Song and D. Wang, “Manufacturing flexibility, business model design, and firm performance”, International Journal of Production Economics, vol. 193, pp. 87 – 97, 2017.

M.S. Sodhi and C.S. Tang, “Strategies and tactics of Chinese contract manufacturers and western OEMs (2001–2011)”, International Journal of Production Economics, vol. 146, no. 1, pp. 14-24, 2013.

M.P. Pe´rez and A.M. Sa´nchez, “Lean production and supplier relations : a survey of practices in the aragonese automotive industry”, Technovation, vol. 20, 665 – 676, 2000.

R. Shah and P.T. Ward, “Defining and developing measures of lean production”, Journal of Operations Management, vol. 25, no. 4, pp. 785 – 805, 2007.

M.A. Marhani, A. Jaapar and N.A.A. Bari, “Lean construction: towards enhancing sustainable construction in malaysia”, Procedia - Social and Behavioral Sciences, vol. 68, pp. 87 – 98, 2012.

E. Sundin, M. Björkman, M. Eklund, J. Eklund and I. Engkvist, “Improving the layout of recycling centres by use of lean production principles”, Waste Management, vol. 31, no. 6, 1121 – 1132, 2011.

G.N. Nyaga, J.M. Whipple and D.F Lynch, “Examining supply chain relationships: do buyer and supplier perspectives on collaborative relationships differ?”, Journal of Operations Management, vol. 28, no. 2, pp. 101 – 114, 2010.

M. Houshmand and B. Jamshidnezhad, “An extended model of design process of lean production systems by means of process variables”, Robotics and Computer-Integrated Manufacturing, vol. 22, no. 1, pp. 1 – 16, 2006.

J. Váncza, L. Monostori, D. Lutters, S.R. Kumara, M. Tseng, P. Valckenaers and H. Van Brussel, “Cooperative and responsive manufacturing enterprises”, CIRP Annals - Manufacturing Technology, vol. 60, no. 2, pp. 797 – 820, 2011.

D. Petrovic, “Simulation of supply chain behavior and performance in an uncertain environment”, International Journal of Production Economics, vol. 71, pp. 429 – 438, 2001.


Refbacks



ISSN : 2590-3551, eISSN : 2600-8122     

Best viewed using Mozilla Firefox, Google Chrome and Internet Explorer with the resolution of 1280 x 800