Study on implementation of one-piece lean line design using simulation techniques: A practical approach

This paper discusses the simulation study carried out for proposing one-piece lean line layout with features of Lean Manufacturing. The lean initiatives that can be addressed are, introducing Kanban replenishment sys-tem, better work-in-process, changing the layout, visual management techniques, standardized work for the re-duction of cycle time, number of workers, number of setups. To improve the layout in a pump manufacturing industry, VISIO 2007 and Pro Model-Process Simula tor Software are used. Pro Model simulation modeling software is a powerful yet easy-to-use simulation tools for modeling all types of systems and processes. Pro Model software is designed to model manufacturing systems ranging from small job shops and machining cells to large mass production, flexible manufacturing systems, and supply chain systems. The study has dis-cussed the lacuna in the existing flow line and has suggested a new one-piece lean line design using the simu-lation software. The validation is carried out by creating the wooden prototypes representing the cells and in-volving the workers to do the assembly of the pump. Standard time study charts are used to calculate the cycle time and change over time.