Sustaining Lean manufacturing in mid-volume, mid-variety environment such as mixed model system poses a few challenges. Typically, these are Cellular Manufacturing Systems in which the prevalence of manual work makes ergonomic studies relevant. Considering the industry's need for productivity improvement while adhering to governmental regulations on manual labour at the workplace, we propose a viable framework that integrates human factors, lean tools and job rotation to seamlessly interface men, machines, and methods.
The study focuses on a configuration of continuous job rotation cell, also referred as Nagare cell, in which workers walk along the line to complete a cycle. In this configuration, the presence of automated or semi-automated equipment hinders productivity and affects workforce utilisation. Suzhal, a configuration with sub cells, is a new layout that overcomes such difficulties. In this study, we examine the hypothesis that Suzhal cell yields higher productivity improvement and provides safety to workmen. We tested this hypothesis in a case study of an automotive enterprise using discrete event simulation. An analytical model is developed for optimum cell configuration (sub cells) corresponding to number of operators. Our analysis, using simulation, shows a significant improvement in throughput, work force utilisation, process cycle efficiency and considerable improvement in safety. From the results, we conclude that the integrated approach aids the implementation of lean ergonomics and promises to improve any industrial processes.
SMS has been continuously evaluated in various industry contexts over the years to test for its agility, fidelity, robustness and ease of implementation. Some of these industries include automotive, niche manufacturing, service, etc. Improvements that have been brought about are process cost reduction; cost of poor quality; process optimisation; manpower optimisation; efficiency improvement; downtime reduction; consumable cost reduction and new product development. SMS is being extensively used by Southern Railways, TVS group, Anand group, etc.
Reference:
V. Balasubramanian, “Process Excellence Using Suzhal Management System (SMS) – Concepts to Practice,” National Health Mission, Chennai, India, February 28, 2017.
