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Optimization of cycle time assembly line for mass manufacturing

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Abstract

This current effort proposes implementing virtual manufacturing in a shop for the automotive industry, specifically for the assembly of VLO (Vehicle Layout) operation, axle drop, engine drop, exhaust system drop/ATS system, and cab drop. The primary objective is to synchronize the material handling system’s frequency (Takt Time) with that of the Electric powered Monorail Hoist System. Different production rates can be achieved by adjusting the combination of process parameters and keeping the process flow among the material handling machinery uninterrupted. An assembly line for chassis was simulated by using varying volume levels. The effectiveness of the system was evaluated with simulated data. Delmia Quest software facilitates in finding problems in process planning by using 3D simulation in place of time-consuming manual processes. The utilization of 3D simulation during process flow design helps to verify equipment motion and spot crashing and smuggling on the assembly line. The manufacturing process was modelled in CATIA® for design, and then simulated in real time using Delmia QUEST for simulation. The proposed effort seeks to improve understanding of production on assembly lines and the many manufacturing methods and steps required during the manufacturing process in order to reduce costs of production and idling while simultaneously increasing productivity. Operator loading accelerated by 5% because of the added 14.18 min of job content, and the target number of vehicles per shift has been achieved.

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Authors and Affiliations

  1. Department of Production and Industrial Engineering, NIT Jamshedpur, Jamshedpur, Jharkhand, 831014, India

    Pankaj Kumar, Shashi Bhushan Prasad & Dharmendra Patel

  2. Department of Mechanical Engineering, K.R. Mangalam University, Gurugram, Haryana, 122103, India

    Kaushal Kumar

  3. Division of Research and Innovation, Uttaranchal University, Dehradun, India

    Saurav Dixit

  4. Department of Management and Innovation, National Research University Moscow State University of Civil Engineering, Moscow, Russia

    Shchepkina Natalia Nikolaevna

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  1. Pankaj Kumar
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  2. Shashi Bhushan Prasad
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  3. Dharmendra Patel
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  4. Kaushal Kumar
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  5. Saurav Dixit
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  6. Shchepkina Natalia Nikolaevna
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Kumar, P., Prasad, S.B., Patel, D. et al. Optimization of cycle time assembly line for mass manufacturing. Int J Interact Des Manuf (2023). https://doi.org/10.1007/s12008-023-01343-3

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