Line Balancing and facility optimization of Machine Shop with Work Study and Simulation Tool

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 07 | July 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 428
Line Balancing and facility optimization of Machine Shop with Work
Study and Simulation Tool
Mr. U. U. Bhosale1, Mr. G. R. Kulkarni2
1Student, KIT’s College of Engineering, Kolhapur, Maharashtra, India
2Professor, Dept. of Mechanical Engineering, KIT’s College of Engineering, Kolhapur, Maharashtra, India
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Abstract – Along with quantity the quality of finished part
is examined strictly for the purpose and application of the
finished part, the quality of production system is also
important. Quality of production system in termsofutilization
of machines and humans involved in system isimportant. Lean
manufacturing concept is all about improving the
performance continuously by eliminating the waste and to
become competitive in production. The study focuses on a
machine shop working in industrial sector with its sister
companies, fluctuations in demands and also new critical
developments for batchproductionarethemainobstaclesthat
shop is facing in their normal routine work. We are studying
the newly introduced batch production system to increase the
productivity and utilization of facilities involved in the system
with work study and simulationtool. Theprocessofmachining
is studied by method study, The standard times are calculated
by time study, the proposed modifications in current working
system are examined using simulation tool FlexSim.
Simulation assists to study precisely the different
manufacturing scenarios and machine arrangements; it gives
sophisticated advantages than other methods like
mathematical method. FlexSim is best way to compare the
results obtained by certain changes in experiments in such
cases.
Key Words: Lean Manufacturing,Method Study,TimeStudy,
Simulation, FlexSim,
1. INTRODUCTION
The Machine shop unit isworkingalmostmorethan20years
in automobile parts and ancillary’s field. Theyhaveachieved
great success in developing and supplying of machining
critical components to the exact needs. In previous stages
industry was not in mass production but working in batch
production. In past few years they are facing fluctuations in
demands and new critical developments for batch
production. These fluctuations lead them into loss of
controlled production, production losses due to improper
capacity planning. Fluctuations in demands and also new
critical developments for batch production are the main
obstacles that shop is facing in their normal routine work.
Due to such reasons, they are failing to meet monthlytargets
also the loss of controlled production, idle machines and
operators, difficulties in manpower planning. Aim of the
study is to observe and analyze the machine shop working
having combination of newly introduced batch andoldmass
production and confirm that the shop is balanced well and
put forward the corrective measures.
Machine shop is facing someproblemslike, Nostandardtime
defined for the stages of machining, WIP-Work in process
inventory present in inaccurate amount, Idleness of
machineries, Failuresinmeetingtheweeklydispatchtargets,
Idleness of workers, Problems faced inmanpowerallocation
and its planning. With the help of Work studyandsimulation
tool we are going to identify the hidden reasons behind
idleness, bottlenecks and provide the suggestions to
minimize it.
2. LITERATURE REVIEW
In most of the industries some common types of wastes
are presentlikedefects,excessproduction,excessprocessing,
idleness, unnecessarymaterialmovements,etc.Thesewastes
may affect as increase in cost of end products. Basically, lean
manufacturing is a bunch of scientific tools which belongs to
common departments present in an industry. Lean
manufacturing is a way of enhancing productivity by
eliminating or reducing these different wastes present in
industries as well as eliminating the non-value adding
activities.[1.1] Reduction in waste results in reduction of
total manufacturing time and improved quality of the
product. There are different lean tools for identification of
sources of wastes in system and to study its effect on overall
system, after the identification someleantoolsarehelpfulfor
study how the wastes can be eliminated. Though the lean
manufacturing is mostly a managerial functionitsawareness
in workshop and lower-level personal is very important to
get the benefits of such philosophies.[1.2] The study of
designed part or product for the purpose of defining the best
suitable method of producing it and also specifying the time
to perform it by the chosen method. Therefore, it comprises
of two areas of study one is method study or motion study
and time study that is work measurement. Method study
known as work method design, it is applicable to new parts
as well as used for existing parts to find better way of
manufacturing the parts that is safe, require less effort, and
time.[2.1] Time study provides the standard specified time
that is the time needed by a worker to complete a part by the
suitable preferred method or the method already defined by
method study. Timestudyisimportantforproperplanningof
manpower, machinery,equipmentrequirementalsomaterial
requirement planning, per unit cost of production, labor

budget, etc. Hence with the application of method study and
timestudy in industries,wecanachievebetteroutput,quality
at low cost and hence productivity can be improved.[2.3] In
simple words VSM is a tool used for creation of material and
information flow map of a product or process. Different
departments in any industryuse value asa wordfordifferent
meanings, mostly production department relates it to costof
production. A valueaddingactivityofaprocessisthatactivity
for which the customer is willing to pay. A value stream
consists of non-value adding activities with all the
manufacturing processes including supportive activities to
convert raw material into finished goods. It is a lean
manufacturingtooltodevelopanefficientproductionprocess
through systematic data collectionandanalysis.[3.1]Atmost
of small and medium scale industries parts are produced in
batch type productionwithprocesstypeoflayout,thisresults
in greater WIP, material handling, difficulties in achieving
delivery schedule targets, frequent changes in set ups which
leads in improper utilization of machinery. For such
situations GT is the technology that adds the advantages of
mass production in to the batch production. [4.1] Line
Balancing, the word ‘line’ used in following case is for
production or assembly line and its balancingmeanstomake
production system smooth and efficient by running all the
operations or machineswithsamepaceordividingtherateof
work among the workstations, workers, and machines
evenly. Also in another way we can say assignment of proper
quantity of machines and workers to each operation to
achieve the required rate of production with less idle time.
[6.1]
3. METHODOLOGY
The main objective of the current machine shop study must
begin by identifying and listing down the problem, then
required data should be gathered for the analysis. The area
where the improvement is needed to be identified based on
the information collected. An analysis should bedonetofind
the exact part that is most likely to be improved. Practical
difficulties during actual implementation will be identified
through trial execution and the working should be verified
by simulation software FlexSim.Discussionmustbemadeon
the results of simulation experiments and its results before
the conclusions.
4. DATA COLLECTION AND PREPARATION
The machine shop unite worksonroughfoundryproductsto
make it full finished part involvingsuperfinishingprocesses.
By listing the parts that the machine shop having regular
demands for the past few years, to understand the working
of machine shop we observe each part, how it passes
through differ machining process, the sequence and type of
material handling systems used, if they move single piece or
form an unite load. And developed the process flows of
respected part that is machined in machine shop. On
collected data and by discussing with shop authorities we
selected MK 25 HUB for further studies considering
economic contributions, manual efforts involved and the
technical considerations.
By collecting all the information and specifications of
machine shop facilities we developed the process flow chart
and geometric layout for the MK 25 HUB.
Fig -1: Geometric layout
[1. CNC06, 2. Vertical Broaching Machine, 3. CNC01, 4.
Deburring Table, 5. Burnishing Machine, 6. Inspection
Table, 7. Grinding Machine]
5. CONCEPTUAL MODEL
As the name itself indicates, model that represents all the
important elements and its characteristics as they exist in
actual machine shop. Man, Machine, Material, Material
handling equipment,inventories,inputorincomingmaterial,
etc. are the main elements of machine shop as we identified
and our machine shop simulation model should have in it.
Fig -2: Conceptual Model

5.1 Selection of Process variables
As the objective is to improve productivity the output of
system is first performance variable, and second is
utilization of machines.
6. WORK MEASUREMENT
Work measurement or simply the time study by video
recording of each machining activity then breaking down
them into small elements then summarizing and adding
allowances to basic time gives the standard cycle times for
the processes involved in machining the Hub. Also the
summery gives the non value addingactivitiesthatshould be
avoided to reduce cycle time or setup timewhichwill impact
positively on total processing time.
Table – 1: Time study summery report for MK25 HUB
Sr
no.
Operation Set
up/Loading
Unloading
Time (sec.)
Process time
(sec.)
1 1st Setup 22 240
2 Broaching 46 30
3 Deburring 2 80
4 2nd Setup 24 80
5 Burnishing 10 41
6 Grinding 24 153
Total 128 624
Total (sec.) 752
Total (min.) 12.53
7. MODEL TRANSLATION
Using FlexSim Express the actual machine shop unite is
imited in flexSim. The dimensional layout in imported and
the elements provided by software fixed resources and task
executers the machines and operators are placed at the
locaton.
Fig -3: Primary Model
Model verification is done by comparing the developed
model with conceptual model andbydeterministicapproach
using average cycle times crossverifyingtheconstantoutput
that system gives on trial runs. Then by using the normal
probability distribution for setup and process times of
machines validated the model comparingtheactual machine
shop dispatches and the output of trail runs ofsystemforthe
same period of time, which will be the stochastic model for
the experiments.
Fig -4: Existing system run for 8Hrs. shift.

120
240
360
480
600
720
59
154
263
360
467
570
120 120 120 120 120 120
59
95 109 97 107 103
0
100
200
300
400
500
600
700
800
Day 1 Day 2 Day 3 Day 4 Day 5 Day 6
WEEK 1
TotalInput TotalOutput Per Day Input Per Day Output
Chart -1: Name System output for a week of 8Hrs. shift.
8. EXPERIMENTATION, RESULTS AND DISCUSSION
Current system shows the output of 59 Hubs. against the
input of 120 for 8Hrs. daily shift. And the utilizationofall the
machines except machine used for 1st setup, also the
inventories remain unfinished at the end of shift.
8.1 Experiment No.01:
Focusing on the inventory levels remained unfinished
decided to run the shift for 12 Hrs. and it shows that the
targets are achieved in fact the system processed the Hubs
more than the requirement but the utilization of machines
and operators remain belove the 50%.
Chart -2: Machine utilization for a week of 12Hrs. shift.
120
276
446
600
772
930
120
156 170 154 172 158
0
200
400
600
800
1000
Total Output Output per day
Chart -3: System output for a week of 12Hrs. shift.
Bottleneck present at the 1st setup of process that idles the
other machines in system. The cycle time is almost double
the other processes hence introducing additional CNC tothe
system to match the pace.
Fig -5: System with additional CNC
Chart -4: Current system Vs. System with additional CNC
This system produces nearly what actually required by the
schedule per day. The output is improved by 21.22%. but
looking at utilization rates the all the machines are under
utilized also the operators are under utilized hence the
system not fulfills our prime objective. Addition of CNC to
the 1st setup the bottleneck is shifted from first two
machines in the system but observed that the two CNC
machines can process basic requirement in half of the shift.
And remain idle for the other half. Hence it is bettertodivide
the system in two groups and run themalternately. Also,can
request for double the input as the system capacity is
increased.
Dividing our system in two groups,
GROUP A : CNC05 and CNC06
GROUP B : Vertical Broaching, CNC01, Deburring,
Burnishing, Grinding Machine.

For the aim of increasing the utilization running the GROUP
A in first 8 Hrs. shift and the GROUP B in second 8 Hrs. shift
of the day.
Fig -6: GROUPA and GROUP B run for 8Hrs. shift
GROUP A
The output of the group A (200) is close to the target
quantity 240. We are suggesting the cycle time reduction, if
possible, for the 1st setup operation with the use ofdifferent
inserts and tooling which can be used at higher speed feed
rates, and the setup time of 22 sec. can also be minimized by
operator training. We are asking to CNC setter for reduction
of cycle tome by 30 sec. and setup time for 10 sec.
GROUP B
The output of the group is 139 which is not feasible, Reason
behind that is the cycle time of grinding machine.Grindingis
the bottleneck operation here, as the input to the process is
240 and the output is 139 HUBs.
Grinding is a finishing process and by studying the process
it seems that the operator is fully involved throughout the
cycle time and there are small possibilities of reducing the
cycle time. Hence, we are looking for the grinding machine
which is under maintenance present near the Grinding
machine involved in the present system.
In this experiment working for removal of bottleneck
present near last process grinding, to tackle the problem
assuming the machine under maintenance present near the
grinding machine is ready for performing same operation as
Grinding Machine 01. Second Modification is the setup and
process time of 1st set up is reduced by 10 sec. and 30 sec.
respectively.
Fig -7: GROUPA and New GROUP B run for 8Hrs. shift
Chart -5: Comparison of all systems experimented
The system run in groups for alternate shift matches the
output to the required per day input and the utilizationofall
the operators and machines involved in processingHubsare
above 70%. It seems that by that modifications all the
objectives can be achieved.
9. CONCLUSIONS
In this study, by video recording and time study standard
times for the processes involved in the machining of MK 25
HUB is calculated. The cycle times and the time study data
can be used as base for the further studies, when ever the
supply and demand fluctuate in the future the data can be
used to set optimum machining system for the HUB.

Table – 1: Expenditures, Results and Expenses
Experimental Details Expenses
Experiment No.01
 Current system run for extra
4 Hrs.
i.e., Daily shift of 12 working Hrs.
 Output – Target achieved
 Machines and Operator
Utilization – Except CNC06
all are under 40%
Six operator
having Avg. daily
wadges 390 Rs.
Worked for
additional 4Hrs.
Total30000Rs.Per
month
Experiment No.02
 Introduced CNC05 in the
system. (bottleneck-CNC06)
 Increases in productivity by
21.22% (for same 8Hrs.)
 Output of 570 Hubs at the
end of week increased to 691
Hubs.
 Machines and Operator
Utilization - Except CNC06 all
are under 40%
Machine Hr.
rate(350) of
CNC05 added to
the expenditure
Total 2800 Rs.
Per day
Total 72800 Rs.
Per month
Experiment No.03
 Dividing system in two
groups increasing input to
240 unites running them
alternately.
 Utilization of all the
machines above 70%.
 Bottleneck present in group
B which gives output of 139
finished hubs against 240.
Machine Hr.
rate(350) of
CNC05 added to
the expenditure
Total 2800 Rs.
Per day
Total72800Rs.Per
month
Experiment No.04
 Introduction of grinding
machine no. 02 in system for
bottlenecking near grinding
operation.
 Daily 240 output after 16
Hrs.
 All machines and operator
utilization above 70%.
Machine Hr.
rate(280) of
CNC05 added to
the expenditure
Total 2240 Rs.
Per day
Total58240Rs.Per
month
Operator 10000
Rs. Per month
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