SYNCHRONIZING ASSEMBLY LINE OPERATIONS IN COTTON GINNING INDUSTRIES TOWARDS REDUCED CYCLE TIME

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 10, Issue 02, February 2019, pp , Article ID: IJMET_10_02_042 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed SYNCHRONIZING ASSEMBLY LINE OPERATIONS IN COTTON GINNING INDUSTRIES TOWARDS REDUCED CYCLE TIME Dr. Ashok G. Matani Associate Professor -Mechanical Engineering Department, Government College of Engineering, Amravati- [M.S.] India Mohd. Sohail Ansari 2 nd Year M.Tech. Production, Government College of Engineering, Amravati [M.S.] Dr. S. K. Doifode HOD - Chemistry Department, Government College of Engineering, Amravati [M.S.] India ABSTRACT Problem-solving and ongoing procedure enhancements are key elements to obtaining quality improvement in business operations. Many process and machine improvement strategies have been suggested and implemented in organizations, where define, measure, analysis, improve and control is mostly applied. Here we aimed at improving the machine productivity of assembly line in a cotton ginning assembly line in an Industry. The tool which is used to improve the productivity of assembly line are time study and method study. Based on this, the study provides data of time required for each assembly processes, sequence of each operations and flow of the product in assembly line. The present study has been done at an industry, a leading manufacturer of cotton ginning machine. The aim of the study is to identify the various problems on the assembly line which causes unnecessary delay in the operations. The problem is found in the assembly line and is solved by work study techniques and it is found that cycle time of bottle neck operation was reduced by 33.05% per trolley Keywords: machine improvement strategies editor@iaeme.com

2 Synchronizing Assembly Line Operations in Cotton Ginning Industries Towards Reduced Cycle Time Cite this Article: Dr. Ashok G. Matani, Mohd. Sohail Ansari and Dr. S. K. Doifode, Synchronizing Assembly Line Operations in Cotton Ginning Industries Towards Reduced Cycle Time, International Journal of Mechanical Engineering and Technology, 10(2), 2019, pp INTRODUCTION 1.1. Productivity Improvement Productivity improvement means reduction in wastage of resources like men, time, material, capital etc. It is the human efforts to produce more profit in terms of less wastage of material, less time consumption in assembly of manufacturing with less inputs of resources provided so that the benefits will become maximum for the organization. Productivity improvement is the key to do the right thing better & improve it continuously. Therefore, it is important to adopt adequate or efficient productivity improvement technique to maximize the machine output with a less consumption of resources Work study Work study investigates the work done in acompany/organization and it aim to find the best andmost efficient way of using all the resources which areavailable i.e. material, man, machine, money etc.work study techniques involve a) Method study and b) Time study techniques Method Study Method study targets at finding the best way of doing thework. Method study involves systematic investigation(which involves recording and critical investigation) of thecurrent method of doing the job so that easy, fast, whichcauses less fatigue to the worker, safe, economical way ofdoing the work can be developed and installed at low cost.this is basically achieved by eliminating the unnecessarymotions which are involved in a procedure of doing thework and the same can also be achieved by changing thesequence of operations or process itself Time study Time study is a technique of work measurement used toestablish time for a qualified worker to carry out specifiedtask under specified conditions and at defined level ofperformance. 2. CASE STUDY The study has been done at an industry, a leading manufacturer of Cotton Ginning Machine. The aim of the study is to identify the various problems on the assembly line which causes unnecessary delay in the operations. The problem is found in the assembly line having six work stations where it is found that there are various operations creating bottle neck on the assembly line. It is desirable that 40 Cotton Ginning machine to be assembled on the assembly line but it is observed that 75% of cotton ginning machine are assembled a day. Thus the concern of this paper is to present the ideas which can beused by the industry to reduce its cycle time of theoperations in its assembly line to enhance theefficiency of the system editor@iaeme.com

3 Dr. Ashok G. Matani, Mohd. Sohail Ansari and Dr. S. K. Doifode 3. OBJECTIVE To identify the operations causing bottle neck in the assembly line. By using the method study technique, identify the problem work stations in the assembly line. Develop a method to solve the problem which is causing unnecessary delay in the assembly line. Conduct time study in the assembly line after implementation of the new method for trial period of 10 days. Suggest new method to the concern personnel in the organisation. 4. STUDIES AT INDUSTRY First step is to determine the operation sequence in each work stations on the assembly line. Observe and identify the cycle time for each operations on all work stations. It is found that sub assembly of the seed channel of the cotton ginning machine took around minutes and the time should be around 10.5 minutes for a trolley in a work station. The problem associated with present method is that the sub assembly of seed channel fitting or tightening of bolts and nuts on workstation 2 are done manually by spanners and cannot be tightened by the torque wrench due to the design constraint. Thus it is observed that due to this manual operation, the overall work station time of the workstation 2 is around minutes which is far greater than the other work stations and also the work station time of station 1 is the least around 3.4 minutes shown in the graph below. Now it is observed that by loose fitting of seed channels at the workstation 1 and manually tightening of the nut and bolts are done in the workstation 2 can decrease workstation time of station 2 to 9.32 minutes and simultaneously increases the workstation time of station 1 to 7.93 minutes i.e. total decrease in time of 4.6 minutes from station 2 and increase in the same on station 1. By implementing the new method, line efficiency of the assembly line increases editor@iaeme.com

4 Synchronizing Assembly Line Operations in Cotton Ginning Industries Towards Reduced Cycle Time Figure Assembly Line Layout of the industry Tables for the cycle time and Work Stations Time with sequence of operations before implementation of the new method. WORK STATION 1 1 Side Frame Cross bar fitting Rail fitting Total workstation time WORK STATION 2 1 Seed channel 1 fitting Seed channel 2 fitting Total workstation time WORK STATION 3 1 Back knife fitting Knife holder fitting Fix knife fitting Seed Guard Jumbo fitting Total workstation time editor@iaeme.com

5 Dr. Ashok G. Matani, Mohd. Sohail Ansari and Dr. S. K. Doifode WORK STATION 4 1 Ratchet fitting Side plate fitting Beater assembly fitting Total workstation time WORK STATION 5 1 Weight lever fitting Gear box fitting Total workstation time WORK STATION 6 1 Gear box plate cover fitting Tables for the cycle time and Work Stations Time with sequence of operations after implementation of the new method. WORK STATION 1 1 Side Frame Cross bar fitting Rail fitting Seed channel loose fitting Total workstation time WORK STATION 2 1 Seed channel 1 tightening Seed channel 2 tightening Total workstation time editor@iaeme.com

6 TIME (IN SECONDS) TIME (IN SECONDS) Synchronizing Assembly Line Operations in Cotton Ginning Industries Towards Reduced Cycle Time Three readings of all six work stations in assembly line before implemenation of new method w/s time (reading 1) w/s time (reading 2) w/s time (reading 3) W/S 1 W/S 2 W/S 3 W/S 4 W/S 5 W/S 6 w/s time (reading 1) w/s time (reading 2) w/s time (reading 3) WORK STATIONS (W/S) Three readings of all six work stations in assembly line after implemenation of new method w/s 1 (reading 1) w/s 2 (reading 2) w/s 3 (reading 3) w/s 1 w/s 2 w/s 3 w/s 4 w/s 5 w/s 6 w/s 1 (reading 1) w/s 2 (reading 2) w/s 3 (reading 3) WORKSTATIONS editor@iaeme.com

7 time (in seconds) Dr. Ashok G. Matani, Mohd. Sohail Ansari and Dr. S. K. Doifode Cycle time of each operations in the work stations and work station time are given above in the table. Thus by using the above table we can calculate line efficiency of the assembly line. Number of work stations = 6 Capacity of assembly line = 40 units per shift per day Total shift time = 480 minutes Unproductive time or worker allowances = 60 minutes Actual production time = Total shift time - Unproductive time or worker allowances = = 420 minutes. For full capacity, time required by one workstation for one trolley = Actual production time = Capacity of plant = 10.5 minutes Therefore, line efficiency before implementation of new method = Actual production time number of workstations largest workstation time 420 = = % Line efficiency after implementation of new method 420 = = % Thus by implementing line new method, line efficiency increases from 50.28% to 71.57%. 600 comparision of the workstation 1 before and after implementation of new method w/s 1 (reading 1) w/s 2 (reading 2) w/s 3 (reading 3) workstation 1 readings w/s time before improvement w/s time after improvement editor@iaeme.com

8 time (in seconds) Synchronizing Assembly Line Operations in Cotton Ginning Industries Towards Reduced Cycle Time comparision of the workstation 2 before and after implementation of new method w/s 1 (reading 1) w/s 1 (reading 2) w/s 1 (reading 3) workstation 2 readings w/s time before improvement w/s time after improvement editor@iaeme.com

9 Dr. Ashok G. Matani, Mohd. Sohail Ansari and Dr. S. K. Doifode It can be seen and compared from the above two graphs that the workstation time of workstation 1 is increased and workstation time of w/s 2 is decreased by changing the operation in the process sheetand thus reducing w/s time of the workstation CONCLUSIONS The results can be concluded that the time required to complete the sub assembly of seed channel in the work station -2 is reduced to 9.32 minutes from minutes. Percentage decrease in time by above study is = = % Thus the productivity of the assembly line of the cotton ginning machine is improved and the line efficiency are increased by the application of work study and change in operation in the process sheet. REFERENCES [1] Ashish Kalra, Sachin Marwah, Productivity improvement in assembly line of automobile industry by reducing cycle time of operations, International Journal of Engineering Research & Technology, 5(5): [2] Swapnil T. Firake, Dr. K. H. Inamdar, Productivity improvement of automotive assembly line through line balancing, International Journal of Technical Research and Applications, 2(3): [3] Cengiz Durana, Aysel Cetindereb, Yunus Emre Aksuc, Productivity improvement by work and time study technique for earth energy-glass manufacturing company, 4 th World Conference on Business, Economics and Management, WCBEM, Science Direct, Procedia Economics and Finance 26(2015),pp editor@iaeme.com

10 Synchronizing Assembly Line Operations in Cotton Ginning Industries Towards Reduced Cycle Time [4] Mayourshikha Pancholi (Bhatnagar), Productivity improvement in chassis assembly line of automative industry by using work study methods, International Journal of Engineering Sciences & Research Technology, pp [5] Shamuvel V.Pandit, Sunil J Kadam, Avinash Kharat, Chetan U Nayakawade, Productivity improvement by application of line balancing, International Journal of Innovative Research in Science, Engineering and Technology, 3(4): [6] Nikhil Verma, Pulkit Trivedi, Vivek Agnihotri, Productivity Improvement in assembly line of an automobile industry, IOSR Journal of Mechanical and Civil Engineering (IOSR- JMCE), 12(4): [7] Dr. A. G. Matani, (2006), Improving water use efficiency by effective water conservation techniques, Indian Journal of Environmental Protection, 26(3): [8] Dr. A.G. Matani, S. K. Doifode, (2015), Effective industrial waste utilization technologies towards cleaner environment, International Journal of Chemical and Physical Sciences, 491(1): [9] Dr. A.G. Matani,(2006), Strategies for better waste management in industrial estates, Journal of Industrial Pollution Control, 22(1): [10] Dr. S. K. Doifode Dr. A. G. Matani (2015), Advanced environment protection techniques by industries: potential for corporate social responsibility activities, Journal of The International Association of Advanced Technology and Science, 15(3):1-8 [11] P Saurabh Jha and Mohd Salman Khan. An Experimental Study on the Automotive Production Line Using Assembly Line Balancing Techniques. International Journal of Mechanical Engineering and Technology, 8(3), 2017, pp [12] Madasamy alias PrabuNivas.C, Venkatesh. J and Kannan. K, Implementation of Special Product & Process Characteristic (Sppc) in A Clutch Cover Assembly Line, International Journal of Mechanical Engineering and Technology, 9(11), 2018, pp [13] S.K. Gupta, Dr. V.K. Mahna, Dr. R.V. Singh and Rajender Kumar, Mixed Model Assembly Line Balancing: Strategic Tool to Improve Line Efficiency in Real World, International Journal of Industrial Engineering Research and Development (IJIERD), Volume 3, Issue 1, January- June (2012), pp [14] K. Parthiban, M. Kumaresan, M. Shantharaj and N.M. Vijay Aravindhan, Reducing the Run out Defect in Cover Assembly Line of Clutch Plate, International Journal of Mechanical Engineering and Technology, 9(11), 2018, pp editor@iaeme.com