New Model Process Development and Cycle Time Achievement for Closure Line Door Assembly

Productivity has been identified as an important role in any organization, especially for manufacturing sectors to gain more profit that leads to prosperity. This paper reports a work improvement project in a car manufacturing company. It involves problem identification at the closure line and proposing recommendation to improve the current situation more efficiently. Based on the observation and data welding constraints has been identified as a major problem and this is caused by the insufficient movements due to material handlings and unbalanced workload. Method improvement technique is used to determine the best method of carrying out a task in order to eliminate the unnecessary movements. Then, line-balancing technique is used to minimize the idle time at every station or the percentage of line balance loss (LBL). In order to rectify this problem time study and motion study was conducted and the core issue was identified and possible suggestions were given and hence ensured better productivity.