Process improvements using lean methodologies in a subassembly line

Abstract

This research study focused on an engine subassembly line at a manufacturing facility. The objective of the study is two-fold: 1) to reduce takt time for engine build by implementing continuous improvement methodologies using lean principles; 2) to minimise the risks this subassembly line is currently prone to because of area congestion, safety issues and ergonomic concerns. Takt time was reduced by 25% by improving the layout using kaizen events based on the input obtained from time studies and motion studies (with spaghetti maps and heat maps). Failure mode effect analysis and three-dimensional static strength prediction program software were used to study the safety risks and ergonomic issues respectively and recommendations were implemented to improve the current working environment.