'Manufacturing design for productivity' :optimization of assembly line for air conditioning control panels

Abstract

This thesis investigates .Manufacturing design for productivity. surveying a case study of an assembly line for air conditioning control panels. The main aim is to investigate the possibilities of operational improvement on the production time in a cost-effective manner. The specific objective of this study is to investigate the relationship between manufacturing design and productivity issues. In order to achieve the objective of this study, a methodology has been developed. First a thorough literature survey is conducted. The use of methods engineering in the factory system is explained, then the relationships between analytical techniques of methods engineering are discussed. Then examples related to subject are investigated. Later on, an assembly line is selected as the case study. An ex-assembly is redesigned by using the concepts of methods engineering. Then both cases are analyzed and discussed in terms of their output capacity and manufacturing time. After the analysis of MTM for redesigned assembly line it is observed that we can reduce production cycle time 20 % at the end of this study. And this development project has been chosen for investment. At the end of this project, we increased the production quantity from 600 pcs. to 800 pcs. Because efficiency of workers have increased with the redesigned assembly line, production of the goods of quantity increased 13 % more than originally calculated. The new assembly line is reduce the operators waiting time and increases their efficiency. The ex-assembly line was covering 13,5m² square it reduce to 3,6 m². Finally, because of efficiency and productivity increase of this study, totally we observed 33 % production increase for the same period of time. By the standardization and the elimination of the operations, and reducing the labor cost the factory could increase its competitive strength.