Design and Optimization of Core Assembly Line for Turbo Charger

Abstract

This study investigates ‘Manufacturing design for productivity’ surveying a case study of an existing assembly line for Turbo charger Core. The main aim is to investigate the possibilities of operational improvement by reducing number of stations in assembly line in a cost-effective manner by reducing the number of grippers used in complete assembly layout. An assembly line is selected for the case study. An existing assembly is redesigned by using the concepts of methods engineering. Then both cases are analyzed and discussed in terms of their output ability and manufacturing time. After the analysis of redesigned assembly layout it is observed that we can reduce average Operation time by 15 % at the end of this study. At the end of this project, we increased the production quantity from 824 to 955 products. Because efficiency of station work has increased with the redesigned assembly line with aid of dual arm robot. The new assembly line reduces the station idle time and increases its efficiency in operation. The existing assembly line was covering 8 m2 it got reduced to 4 m2 approximately in optimized layout. It is observed 15.89% productivity increased for the same period of time. By the standardization and the elimination of the station operations, and reducing the labor cost the company could increase its competitive strength through the optimized layout design.