J. H.Bhangale
A. M. Mahalle
Abstract
To survive in global auto components manufacturers' competition, SMIL, Nasik, India is in phase of restructuring, modification of existing shop floor cells and elimination of bottleneck machines. Problems identified in existing layout are low manpower utilization, more time for material handling. high WIP inventory and space utilization. The objectives of the research are to reduce throughput time, to increase the target of manufacturing component and completion of target as per demand, to maximize manpower utilization, to minimize space utilization, to reduce manpower requirement. Methodology includes analysis of existing layout, process sequence analysis, planning and relocation for new layout considering optimal distance between machines, optimal material handling route and analysis of proposed layout. Results shows improvement in parameters like a) Manpower utilization is increased from 72% to 92%, b) Reduction of WIP Trolleys from 14 to 02 per assembly line i.e. Total cost saving for Trolleys in Proposed Layout is Rs. 5,40,000 per annum, c) One piece flow i.e. no pending work between two stations, d) Reduction of eleven operators per shift. i.e. 22, operators per month (for two shift) results in cost saving of Rs. 52, 80,000 per annum, e) Second economical impact is reduction of one shift per day to achieve same production target as in existing layout i.e. instead of three shift per day, target achieved in two shift per day results in huge cost saving per annum, 33% approximately, f) Machine utilization increases up to 100%, g) No backtracking of material i.e. Rescheduling decisions are avoided, h) With reduction waste in terms of setup time, waiting time, work in process inventory results in improvement of productivity, i) Production target increases due to shorter through time which result into the return business from automobile manufacturers who are satisfied due to shorter throughout time, j)Saving in space is 34.24% by proposed layout implementation due to redesign of layout and combining multiple operations into single operation using new technology and k) Scope for company to run third shift for additional production as per existing or new customer requirement i.e. profit margin will increase by 33% per annum compare to existing conditions.
Keywords- Modelling; simulation; automobile plant; redesign; restructuring.