Reduction of Cycle Time in Vehicle Engine Assembly Line Using Karakuri Kaizen
Keywords:Cycle Time, Non-Value Added Activity, Process Activity, Mapping, Karakuri Kaizen, Vehicle Engine.
Just In Time (JIT) based automotive manufacturing companies use the takt time and cycle time as indicators of their manufacturing performance. This study explores the vehicle engine assembly line for Station 2 Cylinder Block Products, which has a cycle time of 184 seconds, while the company targets a 180 second for takt time. Though ideally, the cycle time should not exceed the takt time. This research aims to identify the Non-Value Added (NVA) activities in Station 2 and minimize them with Karakuri Kaizen. The results of the Process Activity Mapping (PAM) show that Station 2 Cylinder Block has 16 Value Added (VA) activities, 19 Necessary Non-Value Added (NNVA) activities, and 7 Non-Value Added (NVA) activities with a manufacturing cycle effectiveness (MCE) 78%. Based on the activity mapping, the researchers find the primary causes and designed a proposed improvement using the Karakuri Kaizen method to reduce two NVA activities. The company can speed up the cycle time at Station 2 Cylinder Block to 180 seconds and the MCE to 80% by implementing Karakuri Kaizen.
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