Abstract
Optimization of flow in non-cyclical areas gains much importance when it comes to practical industrial applications. The present work covers an extensive Study, Analysis, Design, and Development of an optimal model of internal logistics operations between Raw Material Stores to Assembly Line at WABCO-India Limited, Ambattur. It is shown that there is a major nonstandard, non-cyclical movement of the water spider from storage to assembly line that is non-value-added. It is found that quantity of the parts delivered by suppliers does not synchronize with production requirements and there is a lot of material mix up/damage and high (Work-in-process) WIP Inventory with container sizes not clearly defined. Communication between Stores to Assembly Line is totally manual. A (Define, Measure, Analyze, Improve, and Control) DMAIC procedure was adopted to solve the above stated issues. Using the first Lean principle of Right Part at Right Time, Standard movement of Water Spider was achieved. Material mix up/damage and WIP Inventory were reduced thereby increasing the productivity by 50%. By standardizing the container sizes and eliminating manual communication Built in Quality was achieved. Principle of shorter lead time was applied to synchronize Quantity of the parts delivered by supplier with production requirements. A potential state implementation model has been developed for cascades on the other bays.
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Jeyaraman, P., Jeeva, R., Niruban Projoth, T., Rohith Renish, R. (2022). Internal Logistics Optimization in the Assembly Line Using Lean Techniques. In: Natarajan, S.K., Prakash, R., Sankaranarayanasamy, K. (eds) Recent Advances in Manufacturing, Automation, Design and Energy Technologies. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-16-4222-7_81
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