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Decoupling for Increased Efficiency
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WVS is a Industrial Engineer, Mechanical Engineer, Automotive Ignition Systems Specialist, Lead Acid and Lithium Battery Consultant with world-class expertise in industrial engineering in supervisory roles, automotive ignition, lead acid battery and lithium battery products.
Speak to this experienced, world-class expert now.
- Call (317) 735-4710
- E-mail wvs@rapid-response-consulting.com
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An automotive parts manufacturer had a small assembly line staffed with six people per shift. There was no flexibility in the line's staffing or output. The line manufactured 420 assemblies per shift (or 1,260 assemblies per day on a three shift basis).
The demand for this product was seasonal in nature. The demand in the spring and summer was significantly greater than the demand in the fall and winter. Also, at this particular site, staffing problems arose when people were absent or when overtime was needed.
This KKAI consultant examined the assembly line with the goals of:
1. making the assembly line more flexible on output and staffing requirements
2. increasing capacity
3. improving productivity
The consultant examined the assembly line and made a detailed analysis of each process using industrial engineering "tools" including:
1. downtime studies
2. cycle time analysis
3. standard data "methods" analysis
4. constraint analysis
5. coupling/decoupling analysis
6. buffer analysis
7. value stream mapping
8. autocad layouts
This KKAI consultant made "autocad layouts" of proposals that would "decouple" the assembly line into "mini-cells" and presented these proposals at "team workshops". The team included manufacturing engineers, plant management, maintenance personnel and hourly personnel. Eventually, the line was decoupled into four mini-cells that could be operated by a staff varying from one to eight people. Small buffers were implemented between the mini-cells.
The advantages were clear. The downtime interaction was virtually eliminated. That is, with the original assembly line, problems with one piece of equipment shut down all of the equipment on the line. Now, if one piece of equipment has problems, the other mini-cells are still running (the individual "problem" piece of equipment can be operated on overtime if necessary – not requiring the whole line). Also, the mini-cells can be operated utilizing eight people during "high season" and fewer people during "off season".
Making the assembly line more flexible increased capacity 21% (from 420 assemblies per shift to 510 assemblies per shift). Productivity improved 25% on a "year to year" basis.
Read other articles by this KKAI Associate:
Cost Reduction Process Analysis
| Industrial Engineer, Mechanical Engineer, Automotive Ignition Systems Specialist, Lead Acid and Lithium Battery Consultant, industrial engineering in supervisory roles, automotive ignition, lead acid battery and lithium battery products. | |
| Resume of KIF | quality assurance, continuous improvement, expert consultant |
| Resume of ZXR | monomer process technologist, expert consultant |
| Resume of EPI | power electronics expert, packaging consultant |
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax