SYSTEMATIC EFFICIENCY IMPROVEMENT BY OPTIMIZING THE ASSEMBLY LINE USING WITNESS SIMULATION SOFTWARE

Abstract

Today’s customers demand high quality, customized goods and services, quickest delivery. This has made the design and management of systems more challenging. Simulation models are used to find various aspects of manufacturing systems. Manufacturing industries need plant layout improvements to meet their customer demands. This paper provides the use of Witness Simulation to design the production of a manufacturing company that reconditions Cam follower for export demand. The objective of the study is to increase the productivity and efficiency of the line. Detail knowledge of the assembly line is must and analysing the present needs is important. Cycle time data is collected by stopwatch for every station of respective assembly line. The bottlenecks of the production line, required man, machine and other major causes of the problems were identified. Modifications in the model structure to improve the assembly line is made to improve the total output. The analysis presented through the simulation here reduce the manpower of assembly line with the same production output of 2500 yield per month.Earlier 26 manpower were present per day, through simulation output, 6 manpower are reduced. The relevance of the study is by planning to optimize resources, cost of company is reduced with better profits. Also VSM and OEE study, helped improve the effectivity and productivity of assembly line. By eliminating the root causes for failure of product, the product has become more reliable. Overall the quality of product is improved to 96.00 percent