Takt Time Research Articles

Lean manufacturing analysis of a Heater industry based on value stream mapping and computer simulation

Manufacturing companies implement lean manufacturing (LM) tools to keep their competitiveness over their competitors by improving the manufacturing system’s productivity. Value Stream Mapping (VSM) is a critical tool for implementing the lean approach, and it can be used to many sectors in industry. The paper aims to implement the VSM approach along with computer simulation for identification and elimination of wastes in a small-scale Heater industry by using lean principles and time-frame formulation through takt time calculation. Based on the future VSM improvements, results showed that production lead time (PLT) reduced from 17.5 days to 11 days, and the value-added time decreased from 3412 seconds to 2415 seconds. Takt time also was decreased from 250 seconds to 192 seconds. Our results are a valuable resource for managers and industrial engineers to improve the productivity of manufacturing in a cost-effective and timely manner.

Process improvements using lean methodologies in a subassembly line

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.

Framework for Sustainable Risk Management in the Manufacturing Sector

Risk management is a huge challenge for business managers especially in the manufacturing engineering sector, and if not proactively controlled can lead to under performance and sometimes cessation of activities for some companies. It is common knowledge that poorly managed risks can have an adverse effect on performance while proactive and systematic control of key risk variables in a business environment could generate successful outcomes. The work carried out here has developed a framework for risk management affordable and suitable for use especially by small and medium size enterprises in the manufacturing sector. Using a combination of Bayesian Belief Network (BBN) and Analytical Hierarchical Process (AHP) search algorithms, it was possible to search and identify key risk indicators that could undermine business performance (measured in terms of cost, time, quality and safety) from a system database, and thereby manage (monitor, identify, analyse, reduce, accept or reject their impact) them. The conclusion drawn from the study is that risk management for a manufacturing process can be successfully achieved if risk factors which have a negative impact on project cost, quality of delivery, lead cycle and takt time and health and safety of workers can be identified using BBN and minimised using the framework developed in this study.

Mixed-Model Assembly Line Balancing in The Process of Assembling Trimming Area to Minimize Workstation Using RPW-MVM Method

The development of an industry that continues to move forward coupled with global competition and openness demands that the company continues to evolve and always make improvements in improving the performance of its production process. XYZ Corp is an automotive company based in Germany that produces premium cars, the car assembly process groove at XYZ Corp is a trimming line, mechanical line and finishing line, XYZ Corp produces A-model, B-model and C-model cars. At this time XYZ Corp not achieving the production target due to the car assembly cycle time on the trimming Line 1 area exceeds the specified takt time. Assembly line balancing is required in the trimming area using Mixed-Model Assembly Line Balancing Problem (MALBP) approach to minimize the number of workstation, in the Trimming area assembly line balancing study using the Ranked Positional Weighted with Moving Target (RPW-MVM) method. Alocation constraint should be added due to machine restrictions that cannot be moved. After assembly line balancing, there was a decrease in the number of workstations to 14 workstations with a line efficiency of 86% and balancing efficiency of 97%.

Line Balancing and Sequencing for Peak Power Minimization

Abstract In the past years, environmental awareness started to bring new production paradigms based on energy efficiency. If it is possible to improve energy efficiency of existing production systems, it should be even more profitable to consider this objective at the design stage. In the context of Paced Production Lines, and given power requirements for operations, it becomes possible to assign more efficiently these operations to stations while respecting other constraints such as maximum takt time and number of workstations. The repetitive nature of paced lines implies that misconceptions implying a high peak power consumption will see this peak power repeated over and over without having large possibilities to correct it. In order to tackle peak power minimization objectives, this implies to consider sequencing of operations in addition to their assignment to workstation which is not classical in line balancing. In this paper, the problem under study is presented with a new specific feature that allows to consider semi-active sequence of operations at each station. In order to address large scale instances, a first metaheuristic approach is implemented and evaluated on an extended dataset from the literature. Results show that it is possible to improve energy efficiency at the design stage of production systems.

Implementation of Lean in Four-Wheel Drive Front Axle Sub Assy line

This project deals with the Optimizing the process and eliminating the waste in Four Wheel Drive front axle sub assembly line. Four wheel drive sub assembly line consist of 20 different sub-assemblies are available. In which Axle housing sub assy takes more time to complete i.e. around 20.8 min which is more than TAKT time. In this most fatigue operation is Bush pressing which is done by manual hammering. Due to the manual hammering process TAKT time increases and improper bush assy into the axle housing which leads to failure in the front axle function which results in warranty claims thus increasing the external cost to the company. As the existing process is manual, the accuracy of the pressing operation is not to the standards, while pressing the bush, there is no assurance of full placement of the bush in the axle, also the fatigue is more, and there may be chances of lack of skill in the work. The interference tonnage is found to be 3 to 4 tonnes and so the intensifier unit for the appropriate pressure is to be designed initially 100% inspection is done after bush pressing to check correct position of bush assy, internal diameter of the bush using gauges, Further through PFMEA critical process are identified for failure .

Takt Time Analysis in Lean Six Sigma: From Conventional to Integration

Lean Six Sigma offers a comprehensive roadmap, tools and technique for continuous business process improvement. Principally, Lean Six Sigma integrates Lean’s principle of “value” and “speed” with Six Sigma’s “consistency” (i.e. variation reduction) concept into the DMAIC (Design, Measure, Analyze, Improve, Control) framework. The integration of Lean and Six Sigma advances the pace of business process improvement. Conceptually, Lean and Six Sigma must be applied side by side from both management (i.e. soft practices) and technical (i.e. hard practices) perspectives. However, empirical research found that prior studies on Lean Six Sigma tends to focus on the study of integration from the soft perspective, such as exploring and confirming the determinants for Lean Six Sigma success as well as the application of Lean Six Sigma processes within varies business environments. There is lack of study on the integration of Lean Six Sigma from hard perspective. Hence, the concept of how Lean and Six Sigma tools could be integrated remains ambiguous because there are no standard guideline that available. As such, based on a Lean Six Sigma project(of minimizing new students registration cycle time)that conducted in one of local private university as single case study, this paper explores how Lean and Six Sigma tools could be integrated based on Lean Six Sigma principle, with the focus on a Lean’s tool, namely “Takt Time Analysis”. Finding from the study suggested that Takt Time Analysis could be expanded from “Lean-based” tools to as “Lean Six Sigma tool” by including process variation and process capability as parameters for analysis. The finding as well as the LSS based Takt Time Analysis methodology developed in this study has descriptive value in terms of studying the integration of Lean and Six Sigma tools that govern continuous business process improvement via Lean Six Sigma.

Mejoras en el desempeño de la línea de producción 560A DA utilizando herramientas del sistema de producción Toyota

El estudio en la empresa “A” se realiza en una compañía líder de fabricación de equipos electrónicos para automóviles, principalmente en sistemas de seguridad y de audio, localizada en Málaga, España. El estudio consistió en mejorar la línea de producción 560A DA (ensamble de radio para el nuevo modelo de automóvil que lanzará Toyota en el 2018) mediante el uso de herramientas de lean manufacturing.
 Se analiza la línea para evaluar los principios de lean manufacturing y encontrar oportunidades de mejora. Al iniciar el estudio el desempeño del balance de línea con 8 operadores era de 72,72% y cada trabajador producía 30 unidades por turno de trabajo.
 Al eliminar mudas, disminuir desplazamientos y mejorar el ciclo de trabajo del operador se logra balancear la línea a 6 operarios aumentando el desempeño de la línea a 84,20% y cada operador produce 33 unidades por turno de trabajo. Se analiza el puesto de trabajo mediante la herramienta “strike zone” con el fin de verificar que las herramientas e insumos se encuentran al alcance del trabajador. Además, se efectúa un estudio detallado de los ciclos de trabajo para así clasificar las operaciones en actividades que agregan y no agregan valor.
 Durante el estudio, se identificó que la estación de prueba “Application” era causa de retrasos en el ciclo de trabajo del operador. Para concluir, se desarrolla una propuesta de ampliación de capacidad; la cual se aprueba para ser implementada en el mes de noviembre dado un aumento en la demanda de radios. El takt time para la línea ampliada sería de 80 segundos y según la propuesta el desempeño de la línea se espera sea de 95,51%.

Utilização da ferramenta mapeamento de fluxo de valor (MFV) para identificação de desperdícios no processo produtivo de uma empresa fabricante de gesso

As indústrias do segmento gesseiro, devido ao alto volume de produção, representam um setor de grande importância econômica e que carece de estudos que visualizem a eficiência do sistema de produção. Assim, a partir da utilização da ferramenta Mapeamento de Fluxo de Valor (MFV), o estudo pôde responder a problemática definida, ou seja, apontar quais os prováveis desperdícios e gargalos que o mapeamento de fluxo de valor pode auxiliar a identificar em uma empresa do setor do gesso. Com base nos estudos de tempos (cronoanálise), observou-se que a operação de calcinação é o gargalo do sistema de produção, apresentando um Tempo Padrão de 6338,5 s, o que representa aproximadamente 55% do tempo total de processamento para produção de um lote com, em média, 95 sacos de 40 kg cada. Logo, ressalta-se a importância de se estudar o processo de calcinação, indicado como processo gargalo, a partir da observação do elevado tempo de ciclo em relação ao takt time, o que acarreta em um desequilíbrio no ritmo para atender a demanda.

Sequential optimisation of reconfigurable machine cell feeders and production sequence during lean assembly

ABSTRACTThis paper presents a manufacturing model for integrating reconfigurable machine cells as feeders of components to a multi-product assembly line exhibiting a prominent lean characteristic; synchronisation with Takt time. Two mathematical formulations in the form of combinatorial optimisation problems are developed to identify the best reconfiguration for the machines by optimum selection of the modules in the cells to minimise the total error with Takt time and then the optimum sequence of assembling the products to minimise the total reconfiguration time and effort. An elitist genetic algorithm (GA) meta-heuristic is employed twice in succession to search the optimal solutions for both the minimisation problems. The best machine configuration found from the first search is utilised further to identify the optimal assembly sequence. A hypothetical data set representing the features and parameters of the model in conformance with any typical mixed-model assembly is presented for illustration of computational procedure. Synchronisation among machine cells and tardiness are considered as performance evaluation measures to validate the effectiveness of the proposed model.

Improvement of Operational Performance through Value Stream Mapping and Yamazumi Chart: A case of Bangladeshi RMG Industry

To secure a competitive position in the global market, the Ready Made Garment (RMG) sector in Bangladesh has been facing various challenges including the improvement of industrial operational performance. Among the various operational issues, balancing the cycle time along the production line is felt to be a common and effective way for enhanced performance. There are numerous exact and approximate methods which have already been proposed and are available in literature for repetitive batch production. Unfortunately such approaches are rarely applied in the real RMG shop floor presumably due to the enormous efforts needed to align with the frequent changes of product lines. Compared to the exact and approximate methods, adoption of lean tools like VSM and Yamazumi chart is highly acclaimed for their simpler and wider applicability with superior capability in addressing and solving the balancing problems. So for balancing purposes of the RMG shop floor an attempt is made to frame and apply an integrated model combining the VSM and Yamazumi chart as presented in this article. Depending on the theoretical framework, operational performance of an RMG shop floor is evaluated upon balancing the cycle time. In doing so, firstly a current state map (CSM) and the corresponding Yamazumi chart are plotted to comprehend the existing operational procedure and analyse the workstation cycle time with respect to the takt time. Using the Yamazumi chart, the workstations are reorganized to reduce or eliminate the non-value added activities, to introduce parallel workstations, and to merge workstations so that a balanced production line is attained. Performance is then assessed by means of Overall Effectiveness of Equipment (OEE), Capacity Utilization and Efficiency. The results as obtained through testing a real life case study of RMG industry, ensure the effectiveness of the integrated system of VSM and Yamazumi chart to identify the wastes, restore the line balance and improve operational performance.

(Invited) Critical Parameters for GW Scale Perovskite PV Manufacturing

A recent NREL white paper proposing a new US Perovskite Energy Consortium states “Fulfilling the world’s demand for PV requires continued exponential growth of production capacity without exponential growth in capital expenditure and remains a major challenge due to the inadequate capital efficiency of PV using existing technologies. There is an opportunity and a need for disruptive and fundamentally profitable technologies to supplement the ongoing growth of the PV manufacturing industry”. Perovskite technology promises high conversion efficiency, low manufacturing cost, and low capital expense (CapEx) to build manufacturing capacity. Fulfilling that promise requires a manufacturing process with a very high throughput. The ability to fabricate perovskite films using low-temperature, solution based methods has been touted as a path to low cost and low CapEx manufacturing, however fast deposition of the perovskite layer alone is not sufficient to create the throughput that transforms the PV manufacturing landscape; an in-line process that integrates the deposition of all the functional layers of the device, as well as cell interconnects and module lamination, is required. Any slow vacuum deposition step (e.g., sputtering ITO for the transparent conductor) or long thermal annealing step (e.g., forming a charge transport barrier by forming a compact TiO2 layer) commonly used in lab-scale perovskite device fabrication must be avoided. Our cost modeling shows that the throughput of a single line needed to get to disruptive CapEx and manufacturing cost will be on the order of 45 m2/min. That results in over 3GW/year production capacity at conservative uptime and yield values. An integrated in-line roll-to-roll (RtR) process with a 1.5m wide web would require all deposition steps to run at 30 m/min; much faster than processes cited in the academic literature for lab scale devices. That line speed is not taxing to most commercially available RtR systems, but practical limitations on oven size means a tight window for drying and annealing steps of all solution coated layers. The challenges of creating high performance transparent conductors, inorganic charge transport and barrier layers, perovskite layers and cell interconnects at those speeds will be discussed. The implied TAKT time is less than 3 seconds for 2m2 modules coming off of a single production line. The final assembly and test operations take much longer for each module, so methods of dealing with the mismatch must be implemented. We will also describe the practical considerations, including material sourcing and process requirements for production at GW scale.

Capacity Enhancement through Value Stream Mapping and Line Balancing Technique in Compressor Assembly Line

In competitive global market, manufacturers are urged to know the customer needs well in advance to serve the customer. Customer satisfaction and on time delivery of products play a vital role in establishing long and healthy relationship. When demand for a product is growing, manufacturer ought to plan their activity well in advance to ensure product availability to customer. Capacity planning is done considering dynamically varying demand of customers. Manufacturers are also continuously thriving to reduce cost by enhancing machine utilization. But, Capacity loss is unavoidable in any manufacturing facility. And also it is basic necessity that production capacity to be enhanced, with production cost in consideration. The study intends to increase the capacity of an assembly line and in parallel optimize the manpower (productivity improvement). It deals with identifying non value adding activities and handling them to enhance the capacity of an assembly plant to meet forecast demand. These improvements achieved by using the lean tool, “Value stream mapping (VSM)” which helps to segregate value addition and non-value addition activities for each machine or work station and also will help in continual improvement. Current and future state mapping of assembly line will showcase the lean waste involved in process, current issues, line imbalance, possibilities of further improvements, gap between takt and actual cycle time, inventory at each assembly points, WIP machines and lead time at each stations. These individual issues are sorted out by generating kaizens at each station, which involves brain storming and expert opinion, involving all members of team. These improvements will spread over the entire process flow chain as small pockets. These many numbers of small pockets of improvements is harvested by using another lean tool, “Line balancing”. Line balancing will improve the overall line efficiency and hence capacity enhancement & man power optimization is achieved. The benefits of value stream mapping followed by line balancing technique had yielded capacity enhancement by 86%, manpower reduction by 28%, productivity improvement by from 1.24 to 1.70 units per person per day, through put time reduced from 325.6 to 259.5 mins, line efficiency improved from 79.7% to 97.9% and VA ratio improved from 33 to 37%.

Perancangan Kapasitas Produksi Produk Electronic Control Unit (Ecu)

The export demand for Electoric Control Unit (ECU) products, which continued to increase by approximately 25% in December 2014, made the company have to review its production capacity. Based on current production capacity data, it is known that the process cycle time is 64.9 seconds while the takt time needed to meet consumer demand is 39.4 seconds for the first production line. With working time included in working hours overtime, this first-line capacity cannot meet production demands. Work measurement is done to get actual time data for capacity calculation. Man machine chart is one of the tools used to determine the production line capacity with the current number of machines and workers. To be able to fulfill the production demand, a capacity design with 2 proposed improvements is carried out, namely: adding a working time of one shift for the first production line or balancing work time between lines. By calculating the results obtained and the costs incurred, the proposal for balancing work time between lines becomes more effective to do.

Modelling and Analysis of Manufacturing Process Layout

Manufacturing layout is an arrangement of more than two elements in a manufacturing plant. Process layout shows the layout of elements which running certain process cycle at a certain sequence. Through simulation software, process layout can be simulated and predicted the outcome of the certain model layout before it is implemented. An activity that is conducted in this study such as time study, line balancing and production line re-layout. Furthermore, lean manufacturing tools such as takt time calculation and Yamazumi chart is utilized in order to improve the mechanism in this study. Commercial software is used in order to simulate a model of manufacturing layout and increase the efficiency in the model. These simulated results were compared with the current process layout. The proposed new production plant layout showed promise in its application. However, approaches and layout models need to be evaluated in application to ensure usability so that it is effective and efficient in its performance. The layout of the proposal has increased overall line efficiency which shows an increase of 19%.

Productivity Improvement of An Assembly Line using MOST and Heuristic

In present global scenario where time and cost have become synonymous with one another, it is important improve the overall performance of the industry. Heavy industries such as automobile industries invest a lot of time and money in establishing manufacturing facilities which demands effective utilization of resources to save time and money. This research is an attempt in an assembly line to analyze and expose the effect of sequencing based on the takt time and its impact over the performance of the line. Initial study involves monitoring and standardization of process time for all operations using Maynard Operation Sequencing Technique. Work is further extended to the concept of sequencing and simulation. Calculated process time are used to sequence the operations based on standard Priority Dispatching Rules such as Longest Processing Time, Shortest Processing Time, Potential Score Method, Followers Based Ranking and a custom developed model based on takt time. Discrete Event Simulation of the assembly line was run for all these sequences and it was found that the model developed based on takt time fetched the best results. The model also showed the maximum utilization, line efficiency among all models and had a much better smoothness index than other models.

Process Optimization and TAKT Time Reduction Through Structured Component Quality Planning (CQP) for Flawless Implementation

In today’s business scenario strategic structuring of an organization with narrowly mapped Roles & Responsibilities helps to drive company’s performance. Every single human endeavor takes a shot at the guideline of complementarily. Nothing is conceivable aside from through co-activity and co-appointment. This is on the grounds that man is fundamentally a social creature. All creatures are supplied with necessities and the satisfaction of these requirements requires joint venture. In any case, in the undertaking to satisfy human needs, once in a while the parts of the undertaking happen to be on inverse sides and in this way there are difficulties in such co-employable ventures. Mankind has an impulse for assets and the sense for sharing isn't similarly solid. Subsequently it happens that public activity is enmeshed in unfriendly interests. Down the ages, the contradicted premiums have been extensively run based on physical quality which enables to command and the absence of it that prompts accommodation: the ownership of land and its absence, the entrance to capital-money sources, and the scholarly and functional capability to sort out and abuse capital from one viewpoint, and its absence, coming full circle in the enterprising premiums set against the premiums of the work force or labor. CQP results in flawless launch with desired parameters.

Utilizing a QI Time Series Study to Inform QI Initiatives for Improving Inpatient Endoscopy Workflow

Inpatient endoscopy workflow is complex due to the need for multidisciplinary care coordination and on-demand scheduling. At our facility, weekday inpatient procedures are performed in dedicated operating rooms (ORs) with anesthesia support, with staff resource changes after 17:00. Delays result in unpredictable schedules and extended work days, negatively impacting patient care and both patient and provider dissatisfaction. This initiative sought to find targetable opportunities to streamline endoscopy workflow and minimize time between cases by utilizing a time-series study, with the goal to decrease days with cases extending beyond 17:00. We conducted an IRB-approved QI (Quality Improvement) retrospective analysis of all weekday inpatient endoscopy cases from 7/2017 through 9/2018. Our primary outcomes were number of cases performed each day and the day’s finishing time, defined as the endoscope-out time for the day’s last case. For all weekday inpatient cases over a two-month period, we conducted a time series study of the processes involved in completing an endoscopic procedure to find the takt time and identify sources of variability. All OR cases are completed with anesthesia support in consecutive order, unless resources are provided to staff other ORs for simultaneous cases. We engaged stakeholders to build a detailed process map, known as a swim lane diagram, and identify barriers in care that lead to delay. The process map for inpatient endoscopy shows key areas of variability and delay (Figure 1). During 315 weekdays over a 15 months period, the total number of cases was 2220, with a mean of 7 per day (SD 2, range 2-17), finishing time of 17:46 (SD 2:23 hours, max 1 am). The time series study included 28 weekdays of OR consecutive cases (176 procedures, 45 of which were same-day add on cases mixed into the caseload). We calculated the mean times of each process step per procedure with total takt time, accounting for whether the patient goes to the peri-op holding (PRA) (Figure 2). The total amount of time for the patient from leaving the hospital room to leaving the OR was 2:38 and 1:53, with and without PRA respectively. The average total OR time per patient, defined as the time of a patient’s OR arrival to the next patient’s OR arrival, was 1:33 and 1:56 with and without PRA respectively, where the latter included transport time. The mean time spent on endoscopy per case was 26 minutes (IQR 12-36 min), which was 26% of the total OR time (from 7:30 to last case endoscope-out). The OR was unoccupied for 31% of total OR time, with an average time between cases of 34 minutes (SD 22 min). There was high variability in caseload and finishing time, and substantial amount of time between cases. The time-series study identified barriers in workflow, which will be targets for improvement with measurable process and outcome metrics. This study shows how quality improvement tools and methods may be used to improve efficiency of inpatient endoscopic procedures.View Large Image Figure ViewerDownload Hi-res image Download (PPT)

Plasma Printing of an AISI316 Micro-Meshing Punch Array for Micro-Embossing onto Copper Plates

Packaging using thermoplastic molding for hollowed GaN chips were requested for a leak-proof micro-joining between plastic molds and copper-based substrates. The design and engineering of micro-textures is a key technology for putting leak-proof packaging into practice. In the present paper, a micro-meshing punch array was prepared using plasma-nitriding-assisted printing. Two-dimensional original patterns were screen-printed onto an AISI316 die substrate and plasma nitrided at 673 K for 14.4 ks (or 4 h). The unprinted surfaces were selectively nitrogen super-saturated to have more nitrogen content than 5 mass% and a higher hardness than 1200 HV. The printed surfaces were selectively sand blasted to fabricate the micro-meshing punch array for micro-embossing. A computer numerically controlled stamping system was utilized to describe the micro-embossing behavior onto copper substrates and to investigate how the micro-textures on the array was transcribed onto the copper. Reduction of takt time as well as flexibility in the micro-grooving were discussed with reference to the picosecond laser machining and mechanical milling processes.

Lean Six Sigma for Quality and Performance Improvement of POH Process of Wagon Wheel CTRB

Due to high competition in present world, every end user of a product demand their products to be delivered to them on time with good quality. Hence it is an objective of every industry to satisfy their customer requirements. In the long run, this can be achieved by continuous and constant process improvements. Lean Six Sigma is an overall quality improvement approach combining and capitalizing the strengths of Six Sigma and Lean Management improvement programs. In CTRB periodic overhaul, several process steps and workplaces are required for the job, the movement of inventory between the workplaces can be very time consuming unless it is suitably planned. The major areas that need great attention in this system are WIP (work in process), Takt time and process variability. In this study, focus is on the application of lean tools and techniques with their principles coupled with six sigma DMAIC methodology. The objective of this study is to identify the best possible tools and techniques to tackle premature failure of CTRBs whilst in service due to early presence of defects which are closely associated to the POH process. It also discusses the methodology generally adopted, tools and techniques used and benefits obtained. By mapping current state of the POH process and takt time, future state improvement can be done in order to reduce cycle time using Lean tools such as Poke-Yoke, Jidoka, 5S, SMED