Layout Design and Industrial Engineering Study for DG Set Engine Assembly Plant
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Key Points
- Shifting of assembly to a new location
- New Shop floor Layout Designing
- Production Capacity ramp-up
- Work measurement using PMTS of all the assembly activity
Client's Challenge
-
Layout designing with incorporating multiple parameters
-
Multi-model Balancing of the assembly lines
PMI's Approach
- Existing facility go through and understanding process flow
- Bottleneck Identification
- Data Collection for Work Measurement
- Data Collection for layout design
- Layout Options Preparation and Discussion
- Layout Marking on shop floor
- Elemental Details Preparation
- Preliminary Analysis Report Preparation
Layout Options & Comparisons
Final CAD Layout
- Safety – Paint Shop at Corner may protect remaining plant in case of fire
- FG Inventory – Dedicated space for FG inventory
- Space – Adequate space for genset and canopy line
- Material Receipt & Dispatch – Smooth Material Receipt from South and Dispatch from north side of large warehouse
- Aesthetic View – Product Gallery at entry followed by assembly line
Comparison - Existing vs Proposed
Existing vs Proposed Line Balancing
Existing:
- Under-utilized Manpower
- Production at 6.7 min Takt
- Uneven Line Balancing
Proposed:
- Increased Manpower Utilization
- Production at 4.01 min Takt
- Stations and Activities are merged for Line Balancing
Recommendations
1. Use of Powered Conveyors to
- Elevate manpower utilization by eliminating manpower dependencies
- Smooth Engine Movement on conveyor without Manpower Interruption
2. To further increase in production,
- Increase in length of oven is recommended
- Automation for coolant and water filling in radiator to reduce cycle time
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