Improvement of the line balancing performance through simulation approach in manufacturing assembly line

Muniady, Murali (2024) Improvement of the line balancing performance through simulation approach in manufacturing assembly line. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

Text (Full text) Improvement of the line balancing performance through simulation approach in manufacturing assembly line.pdf - Submitted Version Download (4MB)

Abstract

This thesis delves into the realm of Lean Manufacturing (LM) and simulation techniques, focusing on improving line balancing in the automotive industry. The backdrop highlights the challenges faced by manufacturers in the competitive global market and underscores the significance of optimizing production processes for efficiency and cost reduction. Recognizing the limitations of traditional methods in addressing system variables, the research employs computer simulation, specifically Arena Simulation, to extend the exploration of line balancing in the apparel industry. The study emphasizes the pivotal role of LM in making manufacturing systems more productive and efficient. Lean principles, such as reducing waste, cycle times, and lead times, are identified as key drivers for improving productivity, cutting costs, and enhancing customer satisfaction. The project targets the implementation of Arena Simulation and Line Balancing (LB) as LM tools to address identified issues in the production system. The problem statement articulates challenges observed in an automotive company, PEPS-JV Sdn. Bhd, including the absence of standard time observation, a scattered and complicated workstation layout, and inefficiencies in the kitting process. The absence of a simulation model for measuring cycle time, process flow, and efficiency prompts the need for a new strategy to deal with product unpredictability. Line Balancing and Arena Simulation emerge as critical tools for analyzing LM waste and ensuring a smooth process flow in the production line. The research objectives outline the development of the production layout using Arena Simulation for data collection, the reduction of bottlenecks through a proposed methodology, and the suggestion of decision-making improvements. The scope encompasses the application of line balancing and simulation activities to identify LM waste and enhance productivity in manufacturing line 4 (3MOA) of PEPS-JV MELAKA SDN. BHD. In the pursuit of a smooth production flow and maximum productivity gains, the methodology involves employing line balancing approaches, simulation technologies, and LM tools such as Bottleneck analysis. The research aims to contribute valuable insights into decision-making after implementing improvements, including workstation reduction and changes in worker positions, to achieve optimal output and operational efficiency.

Actions (login required)

View Item