Lean Manufacturing for Productivity Improvement

Abstract

This Paper describes improvement in functioning of water pump in assembly line. By using Lean manufacturing tools like Poka –Yoke, the performance of assembly line should be improved. Programming of all five stations is done in Mitsubishi Nexgen PLCs and Mitsubishi HMI Ms60ct Software. Main Objective of project is reduction in lead time by programming of the stations which will lead to improve productivity, minimizing scrap cost, reduces human element so to prevent from human errors. Two subs- Stations are directly connected to the external devices like Leak testing Unit F-510 and 2D marking. The experiment results explain 35 seconds gap between manual and proposed method operation. Comparison of figures of scrap cost shows that D-Plug substation has high rejection level. Accuracy can be improved of water pump in automatic mode as compared to manual mode.