Throughput improvement by redesigning the mixed model assembly line using simulation

This paper highlights the case study of redesigning the mixed model assembly line. Discrete event simulation approach is used to give the effective solution to the problem. The aim of this paper is to redesign the assembly line and use of simulation environment in the production line, modular fixture design, optimisation of work assignment and further computer simulation for the determination of the optimal solution like production rate of the existing and then redesigned system by reducing the takt time of the line. A welding machines manufacturing company has a mixed model assembly line. Different models of the machine are assembled on the assembly line. In this paper, the Maynard operation sequence technique (MOST) work study is carried out to analyse and minimise the NVA activities. Further, WITNESS and ARENA simulation carried out to study the bottleneck operations and optimisation of work assignment to increase the production rate with less NVA activities. The results of the combination of the line balancing by changing the work assignment, redesigning the line and further process simulation raises the production rate of the process up to 20%.