Implementation of Takt Time to Improve workflow in small and medium industries
The manufacturing industry is becoming increasingly technological and complicated. As a result, the margin for error is growing. The industry can no longer afford to rely on informed estimates when it comes to complex system design. That is why, in order to avoid costly mistakes and adjustme
2025-06-28 16:27:47 - Adil Khan
Implementation of Takt Time to Improve workflow in small and medium industries
Project Area of Specialization Mechanical EngineeringProject SummaryThe manufacturing industry is becoming increasingly technological and complicated. As a result, the margin for error is growing. The industry can no longer afford to rely on informed estimates when it comes to complex system design. That is why, in order to avoid costly mistakes and adjustments, some dependable and solid approaches or instruments are essential. Line balancing and debottlenecking are two of these ways.
Balancing production lines is a critical objective for manufacturing firms to boost productivity by reducing cycle time or the number of workstations. The balance problems govern the assignment of jobs to workstations to meet the goal objectives. The common practice in production line balancing is to allocate jobs to workstations in such a way that each total duration of assigned tasks to each workstation has an equal line takt time.
Debottlenecking is the technique of finding and eliminating blockages that generate inefficiencies or other operational challenges. These inefficiencies might appear in output and energy consumption, necessitating a detailed analysis of existing systems and how they can be improved efficiently and cost-effectively. When attempting to debottleneck an issue, space constraints, money, and downtime lengths must all be considered. Placement of skidding modules inline, modification of a segment of an existing section, or replacement of a complete section are all possible solutions.
Project ObjectivesThe proposed study aims to adjust cycle time to meet demand and improve customer satisfaction levels.
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Time & motion study of CD-70 Cylinder Production line to identify the bottleneck.
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To apply debottlenecking & line balancing techniques to remove bottlenecks and improve the workflow of the line.
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improve the efficiency of the process by removing different types of wastes.
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productivity of the processes will increase with the increase in efficiency.
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Underutilization of the resources is addressed and the machines which are underutilized its utilization is increased by maximizing the resource utilization techniques.
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Quality improvement by applying lean"s proper technique 5S and 6Sigma Techniques.
The methodology of this study is based on the techniques of line balancing and debottlenecking.
Industries in Pakistan are facing demands based on quality shortages and green manufacturing is hardly improvised. Taking on this inspiration, a project comprised of balanced imperfect green manufacturing is worked on for FYP. A very well-established and articulated automotive industry is selected in this regard, and the specified area of study within the sector is the CD-70-cylinder production line. Pinpointing the issue, it has a greater cycle time than the takt time of the line. Moving on to the methodology, a time & motion study of the line is to be conducted which will enable the identification of bottlenecks in the production line. After identification of bottlenecks, our main objective will be to remove bottlenecks and balance the production line by applying proper line balancing and debottlenecking techniques.
The methodology begins with a detailed investigation of the methods and techniques used in a small-scale automobile component manufacturing firm, and the problem was determined through additional data analysis. The data was collected through Time & Motion study for debottlenecking and Production Line balancing to improve productivity, efficiency, and applying lean manufacturing techniques to strive for green manufacturing and approaching the cycle time to takt time to balance inventory and gain customer satisfaction.
Here's a rundown of the topics and techniques we'll be using in our FYP.
Time and motion studies is the scientific study of the conservation of human resources in the search for the most efficient method of doing a task
A bottleneck is a point of congestion in a production system that arises when workloads arrive at a rate that exceeds the capacity of the production process. Inefficiencies caused by the bottleneck frequently result in delays and increased production costs.
Line balancing is a production approach that includes matching the production rate to the takt time by balancing operator and machine time.
Takt time refers to the pace at which components or goods must be manufactured to fulfil consumer demand.
Green Manufacturing is the technique in which workers use fewer natural resources, reduce pollution and waste, recycle and reuse materials, and moderate emissions in their processes.
Benefits of the ProjectThrough our study, industry will be able to implement our techniques to meet the demand and improve customer satisfaction levels. Productivity, Efficiency and Qulity of the Product will also be improved.
By applying Proper techniques of lean manufacturing 6Sigma, 5S, line balancing and time and motion studies we will be able to improve Productivity, efficiency and Quality of the Product and reduce waste to conserve energy and prevent pollution. This is accomplished by reducing or completely removing hazardous substances produced as byproducts during the manufacturing process this is also done by implementing green manufacturing techniques.
Technical Details of Final DeliverableThe manufacturing industry is becoming increasingly technological and complicated. As a result, the margin for error is growing. The industry can no longer afford to rely on informed estimates when it comes to complex system design. That is why, in order to avoid costly mistakes and adjustments, some dependable and solid approaches or instruments are essential. Line balancing and debottlenecking are two of these ways.
Line balancing is a production approach that includes matching the production rate to the takt time by balancing operator and machine time.
Takt time refers to the pace at which components or goods must be manufactured to fulfil consumer demand.
If the production time for a certain manufacturing line is precisely equal to the takt time, the line is perfectly balanced. Otherwise, resources should be shifted or reconfigured in order to eliminate bottlenecks or surplus capacity. In other words, the number of personnel and machines allocated to each task in the line should be rebalanced to get the best possible output rate.
A bottleneck is a point of congestion in a production system that arises when workloads arrive at a rate that exceeds the capacity of the production process. Inefficiencies caused by the bottleneck frequently result in delays and increased production costs.
Final Deliverable of the Project Software SystemCore Industry ManufacturingOther Industries Others Core Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 54344 | |||
| Simulation Software Activation | Equipment | 2 | 17172 | 34344 |
| Stop watch | Equipment | 3 | 3000 | 9000 |
| Time Study Board, Sheets, Calculatoretc | Equipment | 1 | 5000 | 5000 |
| Travelling | Miscellaneous | 2 | 3000 | 6000 |