Optimization of cycle time assembly line for mass manufacturing

• Published in: International journal on interactive design and manufacturing 2024-07, Vol.18 (5), p.2831-2842
• Main Authors: Kumar, Pankaj, Prasad, Shashi Bhushan, Patel, Dharmendra, Kumar, Kaushal, Dixit, Saurav, Nikolaevna, Shchepkina Natalia
• Format: Article
• Language: English
• Subjects: Assembly lines; Automation; CAE) and Design; Computer-Aided Engineering (CAD; Cycle time; Design; Electronics and Microelectronics; Engineering; Engineering Design; Exhaust systems; Industrial Design; Instrumentation; Lean manufacturing; Manufacturers; Manufacturing; Materials handling; Mechanical Engineering; Methods; Monorails; Original Paper; Planning; Process parameters; Process planning; Product development; Production methods; Productivity; Research & development expenditures; Simulation; Software; Three dimensional flow; Three dimensional motion; Time synchronization
• ISSN: 1955-2513; 1955-2505
• DOI: 10.1007/s12008-023-01343-3

This current effort proposes implementing virtual manufacturing in a shop for the automotive industry, specifically for the assembly of VLO (Vehicle Layout) operation, axle drop, engine drop, exhaust system drop/ATS system, and cab drop. The primary objective is to synchronize the material handling system’s frequency (Takt Time) with that of the Electric powered Monorail Hoist System. Different production rates can be achieved by adjusting the combination of process parameters and keeping the process flow among the material handling machinery uninterrupted. An assembly line for chassis was simulated by using varying volume levels. The effectiveness of the system was evaluated with simulated data. Delmia Quest software facilitates in finding problems in process planning by using 3D simulation in place of time-consuming manual processes. The utilization of 3D simulation during process flow design helps to verify equipment motion and spot crashing and smuggling on the assembly line. The manufacturing process was modelled in CATIA® for design, and then simulated in real time using Delmia QUEST for simulation. The proposed effort seeks to improve understanding of production on assembly lines and the many manufacturing methods and steps required during the manufacturing process in order to reduce costs of production and idling while simultaneously increasing productivity. Operator loading accelerated by 5% because of the added 14.18 min of job content, and the target number of vehicles per shift has been achieved.