Car lamp manufacturer, southern Poland
Production line design: 6% more output per day
A plant that makes lamps for passenger cars, with 270 people on two shifts. Its processes are injection molding, painting, electroplating, assembly, labeling, quality control and packaging. The building has 28,000 m² and the warehouse 12,000 m².
+6%
daily output compared with a linear layout
3
layout variants compared
1 week
for the whole analysis
Task
Design a new production line layout with the best throughput and labor efficiency. The analysis had to include the time material spends moving between workstations and intermediate warehouses, the average production time and the line output per hour.
Work
What was done
- Built a digital twin of the material flow.
- Set the working times of the workstations from the times in the project.
- Set standard speeds on the transport routes, including braking and acceleration of the trucks.
- Defined animation paths for the whole material flow.
- Prepared assumptions for three layout variants and compared material flow times and output.
Results
Results and benefits
Results
- The best layout placed the buffer warehouse in the middle, between production and assembly.
- Its average material flow time was not the shortest, but daily output was on average 6% higher than in a linear layout without an intermediate warehouse.
- The other layouts lost output because semi-finished parts waited to be picked up between processes.
Benefits
- A multi-variant analysis of the line in one week.
- The analysis covered both material flow and production capacity for the planned order mix.
The facts and numbers come from the case study published on dbr77.com. Read the original
Video
The case study on video
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Product features used
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