Improving the Quality and Productivity of Steel Wire-rope Assembly Lines for the Automotive Industry

Abstract The automotive industry is one of the most demanding sectors in the global market, since it requires a systematic increase in productivity. In the current economic scenario, the challenges at hand are great, demanding a reduction in costs and an increase in competitiveness, without investment. In order to address this situation, the only solution lies in the optimization of the product and/or processes. This study was developed in order to improve the assembly lines of the steel wire-ropes used to control some of the basic functions in cars, such as the elevation of car-door windows and so on. By applying Lean and PDCA methodologies based on an action plan, it was possible to ensure the implementation of some of the developed solutions, as well as the subsequent processes, and the registration of these as a record for the future. The performance of efficiency was dramatically increased by this study.

[1]  Ngoc-Hien Do,et al.  Re-engineering Assembly Line with Lean Techniques , 2016 .

[2]  A. Moreira,et al.  Single Minute Exchange of Die. A Case Study Implementation , 2011 .

[3]  Juthamas Choomlucksana,et al.  Improving the Productivity of Sheet Metal Stamping Subassembly Area Using the Application of Lean Manufacturing Principles , 2015 .

[4]  Diana Sánchez-Partida,et al.  A case study: SMED & JIT methodologies to develop continuous flow of stamped parts into AC disconnect assembly line in Schneider Electric Tlaxcala Plant. , 2015 .

[5]  Jeffrey K. Liker,et al.  The Toyota way : 14 management principles from the world's greatest manufacturer , 2004 .

[6]  Michael L. George,et al.  Lean Six Sigma : combining Six Sigma quality with lean speed , 2002 .

[7]  S. Spear.  Learning to lead at Toyota. , 2004, Harvard business review.

[8]  Jafri Mohd Rohani,et al.  Production Line Analysis via Value Stream Mapping: A Lean Manufacturing Process of Color Industry , 2015 .

[9]  Jeffrey M. Alden,et al.  Agile manufacturing systems in the automotive industry , 2004 .

[10]  Leonardo Rivera,et al.  Measuring the impact of Lean tools on the cost-time investment of a product using cost-time profiles , 2007 .

[11]  S. Syath Abuthakeer,et al.  Implementation of Lean Tools and Techniques in an Automotive Industry , 2012 .

[12]  Tomaso Poggio,et al.  Learning to see , 1996 .

[13]  Eric Costa,et al.  AN INDUSTRIAL APPLICATION OF THE SMED METHODOLOGY AND OTHER LEAN PRODUCTION TOOLS , 2013 .

[14]  Dimitris Mavrikios,et al.  A perspective on manufacturing strategy: Produce more with less , 2008 .

[15]  Amir Azizi,et al.  Designing a Future Value Stream Mapping to Reduce Lead Time Using SMED-A Case Study☆ , 2015 .

[16]  R. Sundar,et al.  A Review on Lean Manufacturing Implementation Techniques , 2018 .