Ms. Nisha Sahu

Dr. Atma Ram Sahu

Raviraj Garg

Dr. R.C. Gupta

Abstract

In this highly competitive market, the manufacturing industry is developing rapidly in terms of productivity and profiting from high-quality products at the lowest cost. In order to minimize product costs, it is necessary to minimize non-value-added (NVA) activities that have no value to the product. Operators perform these activities on the assembly line during operation and waste their energy. In many manufacturing industries, multiple products are assembled on the final production line and contain NVA. This research paper using principles of elimination, combination, rearrangement and simplification (ECRS) with the help of time study to increase the productivity of vibratory compactors by eliminating non-value-added activities and the number of workstations. To verify productivity improvement operations, case studies in the automotive and heavy machinery industries were examined, in which the assembly process was analyzed in detail and imbalances were observed. To solve these problems, the study of a stopwatch on the assembly line was completed, the workload of the operators was calculated, and the activities were assigned to the operators on the assembly line according to the takt time so that workers are not overloaded with their work on the assembly line and perform their tasks without fatigue. The new balanced production line is designed to reduce the number of jobs from 13 to 8, thus simplifying the process and eliminating unnecessary activities, reducing the number of workers from 27 to 17 and shortening the production time from 504.3 minutes to 405 minutes, and productivity increased from 6 to 8 vehicles per day.

Keywords- Non value-added activity; ECRS; Unbalancing; Time study; Throughput time