EVENT
IE Open house event, 2014. UET Taxila
Title of the project:
INTEGRATION OF SIMULATION, QUALITY CONTROL & ERGONOMICS
FOR PERFORMCE IMPROVEMENT OF SEMI-AUTO INDUSTRIES
Abstract:
In order to make a LEAN Organization, Integration of simulation, quality control and Ergonomics, is a novel approach that
is used to optimize the service level, utilization, throughput rate, cycle times, wait times, rejec-tions, reworking costs, profits,
motivations through an integrated framework. Simulation helps to find the Bottle-neck in system and then alternatives are
generated to optimize above parameters. Simulation can give optimi-zation up to a limit, after that it indicates that now it is
time to work on quality control. Quality control uses six sigma, process capabilities and learning curves to analyze the
current quality level. The reasons of reworking and rejections are then evaluated and prioritized. After this, ergonomic
evaluation is done to remove these causes using ergonomic laws and tools. Design of experiment uses the outputs from
ergonomic evaluation to validate the root cause of rejections and reworking with a confidence level of 95%.
Objectives achieved:
- Reduced the reworking and rejection rates plus cost.
- Increased the utilization and service level.
- Improved the sigma level of company to compete internationally.
- Found the group of operators who were mainly responsible for reworking and rejections.
- Found the effect of environment on productivity.
- Found reasons of low motivation.
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