Productivity Improvement for Cast Iron Burner Production Line A Case Study at TMN Machine and Foundry Co., Ltd.

Abstract

The objective of this research it to improve productivity for cast iron burner production line from 5,000 to 8,000 sets per month by eliminating and reducing non-value added task including bottle neck, wastes from delay, excess motion, defect, rework as well as decreasing raw material transportation distance and time. This research implement 7 QC tools for data collection and problem cause analysis. Moreover, line balancing, plant layout, work study and ECRS techniques are main tools for production improvement. The result shows a capability to control cycle time not exceeding takt time for all stations. Working stations are reduced to 14 stations which accounts for 40%. Workers are reduced to 14 persons which accounts for 40%. Total cycle time can be decreased 17.55 minutes which accounts for 64.33%. The average defect is reduced to 0.16%. The new plant layout can reduce materials transportation distance 253.5 meters which accounts for 72.53%. The process capacity reaches 8,000 sets per month. Labor productivity index increases 69.23%. Raw material productivity index increases 3.85%. The total production index increases 13.04%. The standard time is set for worker.