Lean methodologies to improve assembly line efficiency: an industrial application
Abstract
Similar to automobile industries, the large earth moving equipment (LEME) industries have a dominant assembly line layout. Improving the assembly line efficiency would improve the productivity of the line. This paper focuses on using lean tools such as time and motion study, kaizen events and spaghetti map to reduce waste in a LEME assembly line. For this research, five zones (or work areas) of assembly were studied and using the lean tools the cycle time was reduced to achieve a 15% reduction in takt time. There were four phases to this research effort: data collection, construction of the process flow map, creation of the spaghetti map, and the implementation of kaizen events. The results from this research demonstrate that waste in an assembly can be identified and removed by studying the process and utilising simple yet powerful lean tools.
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Kochańska, J., Burduk, A., Markowski, M., Kłusek, A., & Wojciechowska, M. (2023) · Sustainability · doi:10.3390/su15021113 · Cited by 15 · see citing works
Application of Spaghetti Diagram in Layout Evaluation Process: A Case Study
Daneshjo, N., Rudy, V., Malega, P., & Krnáčová, P. (2021) · TEM Journal · doi:10.18421/tem102-12 · Cited by 7 · see citing works
“For this purpose, a video was taken and the analysis was performed using Assembly Operation Analysis [7], [8].”
Method
- Authors
- Kanaganayagam, K., Muthuswamy, S., & Damodaran, P.
- Affiliations
- Northern Illinois University (US)
- Venue
- International Journal of Industrial and Systems Engineering
- Publisher
- Inderscience Publishers
- Published
- 2015
- Volume
- 20
- Issue
- 1
- Pages
- 104
- ISSN
- 1748-5037 (ISSN-L)
- 1748-5045
- OpenAlex
- W2009169266
- Cited by
- 15
- References
- 0
- Citations by year
- 2025: 1 · 2024: 2 · 2023: 2 · 2022: 4 · 2021: 1 · 2020: 2 · 2019: 2 · 2016: 1
- FWCI
- 0.73
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- International Journal of Industrial and Systems Engineering (publishedVersion)
- RePEc: Research Papers in Economics (submittedVersion)
- Topics
- Social Sciences › Business, Management and Accounting › Management Information Systems › Quality and Supply Management
- Physical Sciences › Engineering › Industrial and Manufacturing Engineering › Assembly Line Balancing Optimization
- Social Sciences › Business, Management and Accounting › Strategy and Management › Management and Optimization Techniques
- Keywords
- lean manufacturing, assembly line efficiency, waste reduction, cycle time reduction, kaizen events, time and motion study, productivity improvement
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