Redesigning the Pump Assembly Layout to Enhance the Productivity

Abstract

This paper discusses the productivity improvement in pump layout. The whole paper deal with the causes for higher cycle time in the production of pump and developing the efficient and effective layout. To accomplish the goal, analyse the cycle time of all work stations by the help of stop watch, with the help of the assembly worker and stop watch the data is collected. The cycle time graph are drawn and used to determine the highest cycle time.  The factors effecting the highest cycle time are bottleneck, length of the line, unnecessary operation like space. The line has three workstations namely Assembly Line, Calibration Process (which has 4 machines) and Packing Line. In Assembly line, the length has been reduced and all of which amounts to an improvement by 43% in the length. In the calibration process a non-value added activity was observed which is manual clamping that caused unnecessary time consumption which could be easily eliminated by introducing Auto clamping. This led to a reduction of cycle time by 34.3%. After implementing the above, improvement in the productivity was observed by 4% from 1000 to 1038 pumps per day i.e., increase in 950 pumps per month and profit by Rs. 33,25,00. All these improvements were evaluated using Lean Line Design and verified through Simulation.