B. Vijaya Ramnath
C. Elanchezhian
Dr. R. Kesavan
Abstract
In order to sustain in the present competitive and global market, on-time delivery, excellent quality and aesthetic are very much essential. The objective ofthis paper is to reduce the cycle time in assembly of master cylinder by implementing various modernized techniques using lean manufacturing concepts. The basic idea of this work is to modify the assembly practice of the brake master cylinder assembly line. This involves synthesis of the current assembly line, spot the areas for improvements, developing new design, analyzing the new designfor stability and to improve the performance of the line. In the existing setup of assembly, there were individual fixtures, tools are to be used for each model of master cylinder assembly. So, whenever the production-plan changes, the entire previous setup offixtures are removed and new complete setup was mountedfor the next model. For removing and re arranging the entire setup offixtures and tools, more time is consumed which result in reduction in productivity. Also, operators felt morefatigue in doing such operation. So, a common setup is planned to accommodate all models and hence to reduce time consumption, increase the productivity and also to reduce the operator fatigue.
Keywords- Cycle Time Reduction, Lean Manufacturing, Productivity, Fixtures.