Ingeniería y Gestión Industrial

Proper lay out gives relief a lot of financial and non financial activates for both users and suppliers. Thus, the propose of this research is to improve the productivity of sewing production line through the layout rearrangement. So that, time, energy and less production gets crashed. The production losing and time consuming due to un proper lay out leads to company unprofitable and customer disaffection. The workers took high energy and time consuming to produce the existing less production because of un proper lay out. Thus, the study was conducted to improve productivities of the company by reducing time consuming process and factors affecting production rate of the company using data from DBL( Bangladesh owned production) manufacturing plc to produce proper lay out. The researcher’s analyzed existing lay out and new lay out to compare based on their efficiency, production and cycle time. so, that the existing lay out efficiency is 21.82%, production1387per day sample 3 blocks, and cycle times respectively for the improved lay out efficiency is 24.14%, production 1546 and cycle time.

Integrated application of lean manufacturing is used for the identification of critical drivers in production of automobile hose. Company’s historical performance is reviewed to enlist problems like overtimes, low productivity, low production line efficiency and suboptimal utilization of resources. To cope with the aforesaid impediments, system constraints were identified through process flows, time study, work element analysis and identification of value added and non-value added activities which were making production line fragile. Constraints were exploited through drum identification, current line balancing of hose assembly line, current targets, manpower requirements analysis, and current line balancing efficiency. The constraints were further elevated through ECRS technique, set-up time reduction, optimized layout, and resource levelling through largest candidate method. Non-Constraint processes were subordinated through largest candidate method of resource levelling. Constraints were further elevated by induction of New Crimping Machine. As a result of this study; production were increased from 365 to 630 Systems per day and overtime was reduced from 315 man-hours/month to zero man-hours.