Challenges

•Complexityin managing Mixed-Model assembly of multiple types of products (excavators androad machinery) on a single line, each requiring different resources, tools,and assembly times.

•Collectingaccurate time study data was challenging due to the complex nature ofoperations and concurrent tasks.

Objectives

•Identifyinefficiencies in both drum fabrication and assembly line operations through acomprehensive time study.

•Providedata-driven recommendations to enhance operational performance and achievebetter synchronization and task sequencing.

Time Study Approach

To address the identifiedchallenges, a thorough time study methodology was employed

Data Collection:

•Observation: Direct observation of drum fabrication and mixed-model assembly linesover multiple shifts.

•Process Mapping: Documented the entire workflow from raw material handling to finalassembly, identifying each step in the production sequence.

•Time Measurement: Used stopwatch techniques and excel template to record the time takenfor each operation.

Analysis:

•Process Variation Identification: Analyzed time data to identifyvariations in task performance.

•Bottleneck Detection: Identified stages in drumfabrication and assembly lines where tasks consistently exceeded standardtimes.

•Workstation Efficiency: Assessed workstation setup toevaluate worker movements, tool placement, and material handling efficiency.

Recommendations

Continuous Monitoring:Establish a system of continuous time study and performance tracking tomaintain optimal efficiency and quickly address any emerging bottlenecks.

Lean Manufacturing Practices:Implement lean principles such as 5S and waste reduction techniques across bothfabrication and assembly lines to eliminate non-value-adding activities.

Technology Integration:Explore automation in repetitive tasks within drum fabrication and digitalmonitoring systems for real-time performance tracking in the assembly lines.

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