Redesign Develop and Optimization of Mixed Model Assembly Line Using Simulation

Abstract

This project highlights the case study of redesigning the assembly line using modular fixture design, optimization of work assignment and further computer simulation of the mixed model assembly line. Discrete event simulation optimization approach is used to select the best system which gives the effective solution to the problem. The aim of this project is to redesign the assembly line and use the “WITNESS and ARENA” environment in the production line, for the determination of the optimal solution like production rate of the existing and then redesigned system by reducing the takt time of the line. Also, in this project, the “MOST (Maynard Operation Sequence Technique)” work study is carried out to analyse and minimize the Non-Value Added activities to standardize the work. Further WITNESS and ARENA simulation carried out to study the bottleneck operations and optimization of work assignment to increase the production rate with less Non-Value Added activities. The results of the combination of the line balancing, redesign, standardization of work by MOST and further process simulation raise the production rate of the process up to 20%.