Optimization of Production Process and Machining Time in CNC Cell through the Execution of Different Lean Tools

摘要

Lean manufacturing is a continuous enhancement technique and a new management approach for small and medium scale manufacturing industries. The primary focus on lean production system is the systematic elimination of non-value added activities from the production process. Value stream mapping is used to map the current state and then helps to identify the sources of wastes in the present system. After identifying the wastes in the current system proper lean tools may be suggested to eliminate these wastes. Work standardization is an important in all manufacturing sector which will give better work procedure, manufacturing flow and solution for variability during production. The main aim of this research is to study the present line balancing layout in CNC machining cell and to develop the proposed line balancing layout to increase the workers utilization. Work standardization was carried out by using the time study and work study with the help of video analysis. Then the non-value added activities were categorized and about 120 minutes of floor to floor cycle time was reduced. Line balancing was carried out to in a machining cell to maximize the operators' utilization by using the one operator- two machine methods. From results it was found that, the man power utilization was increased about 70%. Hence, the total cycle time and non-value added time has been reduced and also the overall productivity was increased to meet the customer demand at the right time.