Throughput enhancement of car exhaust fabrication line by applying MOST

In the fiercely competitive world market of today, manufacturers are facing increasingly tougher challenges and are compelled to find ways for productivity enhancement wherever possible in the whole supply chain. Nevertheless there are many facets in business process which can be explored for possib...

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Main Authors:	Hanash, Ebrahim, Karim, A.N. Mustafizul, Tuan, SaravananTanjong, Mohiuddin, A. K. M.
Format:	Conference or Workshop Item
Language:	English English
Published:	IOP Publishing 2017
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/56363/ http://irep.iium.edu.my/56363/ http://irep.iium.edu.my/56363/ http://irep.iium.edu.my/56363/1/Hanash_2017_IOP_Conf._Ser.__Mater._Sci._Eng._184_012022.pdf http://irep.iium.edu.my/56363/7/56363_Throughput%20Enhancement%20of%20Car%20Exhaust%20Fabrication%20Line_Scopus.pdf

id	iium-56363
recordtype	eprints
spelling	iium-563632018-03-22T09:05:21Z http://irep.iium.edu.my/56363/ Throughput enhancement of car exhaust fabrication line by applying MOST Hanash, Ebrahim Karim, A.N. Mustafizul Tuan, SaravananTanjong Mohiuddin, A. K. M. TJ Mechanical engineering and machinery In the fiercely competitive world market of today, manufacturers are facing increasingly tougher challenges and are compelled to find ways for productivity enhancement wherever possible in the whole supply chain. Nevertheless there are many facets in business process which can be explored for possible improvement, an immediate focus goes for the involved processes to re-engineer the activities in different workstations for an efficient and balanced assembly or fabrication line. In this paper an industrial case on fabrication line of a car exhaust system is presented to illustrate the scope of improvement by applying the MOST (Maynard’s Operation Sequence Technique) in streamlining the activities followed by assembly line balancing (ALB). The whole process of conducting various tasks is investigated to find out the lapses or wastes, to search for better option and to set the standard times for the tasks. Then individual workstation time is worked out by summing up the standard times of the involved tasks or activities and the concept of ALB is attempted to balance the fabrication line. So by possible reduction or elimination of the identified wastes or lapses workstation times including the bottleneck station are lowered. As a result the throughput of car exhaust systems is enhanced. According to the current practice, the Takt time is set at 3 minutes. However, upon an analysis through use of the MOST, the bottleneck station time is found to be as low as 1.27 minutes. Thus an opportunity of meeting the current level of demand with significantly lower workforce (with 2 operators instead of 5) is revealed. Alternatively, if necessary, an increased workload can be assigned for the current level of workforce. Moreover, with proper distribution of activities among the workstations using the concept of ALB, the line efficiency is found to be improved. So the line balance loss in the current setup of production line is also possible to be largely reduced. Thus daily production of car exhaust, if modified with suggested changes with the current workforce, could be more than double compared to the current daily output. Hence, effectiveness of the MOST followed by ALB applications to expose and remove the operational wastes in the work flow is reiterated with enhanced throughput. IOP Publishing 2017-04 Conference or Workshop Item PeerReviewed application/pdf en http://irep.iium.edu.my/56363/1/Hanash_2017_IOP_Conf._Ser.__Mater._Sci._Eng._184_012022.pdf application/pdf en http://irep.iium.edu.my/56363/7/56363_Throughput%20Enhancement%20of%20Car%20Exhaust%20Fabrication%20Line_Scopus.pdf Hanash, Ebrahim and Karim, A.N. Mustafizul and Tuan, SaravananTanjong and Mohiuddin, A. K. M. (2017) Throughput enhancement of car exhaust fabrication line by applying MOST. In: 3rd International Conference on Mechanical, Automotive and Aerospace Engineering 2016 (ICMAAE’16), 25th-27th July 2016, Kuala Lumpur, Malaysia. http://iopscience.iop.org/article/10.1088/1757-899X/184/1/012022 10.1088/1757-899X/184/1/012022
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Hanash, Ebrahim Karim, A.N. Mustafizul Tuan, SaravananTanjong Mohiuddin, A. K. M. Throughput enhancement of car exhaust fabrication line by applying MOST
description	In the fiercely competitive world market of today, manufacturers are facing increasingly tougher challenges and are compelled to find ways for productivity enhancement wherever possible in the whole supply chain. Nevertheless there are many facets in business process which can be explored for possible improvement, an immediate focus goes for the involved processes to re-engineer the activities in different workstations for an efficient and balanced assembly or fabrication line. In this paper an industrial case on fabrication line of a car exhaust system is presented to illustrate the scope of improvement by applying the MOST (Maynard’s Operation Sequence Technique) in streamlining the activities followed by assembly line balancing (ALB). The whole process of conducting various tasks is investigated to find out the lapses or wastes, to search for better option and to set the standard times for the tasks. Then individual workstation time is worked out by summing up the standard times of the involved tasks or activities and the concept of ALB is attempted to balance the fabrication line. So by possible reduction or elimination of the identified wastes or lapses workstation times including the bottleneck station are lowered. As a result the throughput of car exhaust systems is enhanced. According to the current practice, the Takt time is set at 3 minutes. However, upon an analysis through use of the MOST, the bottleneck station time is found to be as low as 1.27 minutes. Thus an opportunity of meeting the current level of demand with significantly lower workforce (with 2 operators instead of 5) is revealed. Alternatively, if necessary, an increased workload can be assigned for the current level of workforce. Moreover, with proper distribution of activities among the workstations using the concept of ALB, the line efficiency is found to be improved. So the line balance loss in the current setup of production line is also possible to be largely reduced. Thus daily production of car exhaust, if modified with suggested changes with the current workforce, could be more than double compared to the current daily output. Hence, effectiveness of the MOST followed by ALB applications to expose and remove the operational wastes in the work flow is reiterated with enhanced throughput.
format	Conference or Workshop Item
author	Hanash, Ebrahim Karim, A.N. Mustafizul Tuan, SaravananTanjong Mohiuddin, A. K. M.
author_facet	Hanash, Ebrahim Karim, A.N. Mustafizul Tuan, SaravananTanjong Mohiuddin, A. K. M.
author_sort	Hanash, Ebrahim
title	Throughput enhancement of car exhaust fabrication line by applying MOST
title_short	Throughput enhancement of car exhaust fabrication line by applying MOST
title_full	Throughput enhancement of car exhaust fabrication line by applying MOST
title_fullStr	Throughput enhancement of car exhaust fabrication line by applying MOST
title_full_unstemmed	Throughput enhancement of car exhaust fabrication line by applying MOST
title_sort	throughput enhancement of car exhaust fabrication line by applying most
publisher	IOP Publishing
publishDate	2017
url	http://irep.iium.edu.my/56363/ http://irep.iium.edu.my/56363/ http://irep.iium.edu.my/56363/ http://irep.iium.edu.my/56363/1/Hanash_2017_IOP_Conf._Ser.__Mater._Sci._Eng._184_012022.pdf http://irep.iium.edu.my/56363/7/56363_Throughput%20Enhancement%20of%20Car%20Exhaust%20Fabrication%20Line_Scopus.pdf
first_indexed	2023-09-18T21:19:30Z
last_indexed	2023-09-18T21:19:30Z
_version_	1777411786155229184

Throughput enhancement of car exhaust fabrication line by applying MOST

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