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https://doi.org/10.1007/s12008-022-01031-8
ORIGINAL PAPER
Abstract
In this present work, the approach is for the adoption of virtual manufacturing in an assembly line system in which the assembly
of Frame, Axle, Engine, Cab Body, and Trim is done over chassis in an automobile industry Trim Chassis and Frame shop.
The major goal is to align the conveyor system’s speed (Takt Time) and the Electrified Monorail Hoist System’s speed with
the conveyor system’s speed. Various process parameter combinations are employed to achieve varied production rates while
maintaining a smooth process flow among material handling equipment. Different volume levels were used to simulate the
chassis assembly line. The system’s efficiency was assessed using simulated data. By substituting manual processes with 3D
simulation, Delmia Quest software aids in the detection of process planning flaws. The use of 3D simulation in the design of the
process flow aids in the verification of equipment motion as well as the detection of crashing and trafficking on the assembly
line system. CATIA® was used to design the assembly line, and Delmia QUEST was used to simulate it in real time. The
proposed effort intends to provide a better understanding of assembly line production and the numerous manufacturing
techniques and procedures that are necessary during the manufacturing process in order to reduce manufacturing costs and
idle time while also increasing productivity. The operator loading improved by 8% after adding 313.92 min of new job content,
while vehicle number increased by 5 vehicles each shift.
Keywords Digital manufacturing · Assembly line balancing · 3D simulation · Trim chassis and frame
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International Journal on Interactive Design and Manufacturing (IJIDeM)
line using a 3D visualization method [8] in order to maxi- process, cost and efficiency [28, 29] analysis, work environ-
mize equipment and labor utilization [9] and reduce idle time. ment resource planning, robots, machine tools, coordinate
Many manufacturing companies switch their traditional and measuring machines, automation dedicated, plant layout and
outdated setups to the assembly [10] line method in order material flow simulation [16], factory automation offline pro-
to increase productivity [11]. Eventually, several changes to gramming, daily production scheduling and line balancing,
the assembly line were implemented in response to the needs and working 3D electronic instructions. QUEST [20] also
and demands of the production [12]. The sole objective of an assists in completing the process with the least amount of
assembly line is to transport a component from one station to machine, human, and material handling [28] equipment. This
another via a conveyor system. Line balancing [13] is a tech- aids the user in calculating the process’ total coat of establish-
nique that is used to achieve this. Line balancing is a critical ment. By coordinating several assembly lines processes with
arrangement of various tasks to a specific workstation with one another, QUEST may also determine the cycle time for a
proper equipment and appropriate unit time so that the pre- process to occur [16]. QUEST aims to improve understanding
ceding process is completed before the next part [14] arrives of assembly line production and the numerous manufacturing
at the same station in order to meet the required production techniques and procedures necessary during the manufactur-
rate [15] and reduce machine and labor idle time [16]. The ing process in order to reduce manufacturing costs and idle
line balancing must be flexible enough to absorb any indis- time while increasing productivity [12, 25].
cretion, whether internal or external, so that any unwelcome
incidence does not disrupt the assembly line [15].
Digital modelling technologies have become entrenched 2 Simulation and modelling
not just in the vehicle manufacturing and production industry,
but also in fashion, modelling, aeronautics, and other fields. The arrangement of the conveyor and Material Handling
These technologies give users the ability to develop a 3D vir- System for EMS was sketched into QUEST to the real dimen-
tual environment of a shop floor and chassis assembly line sioning based on the data provided by the process planner.
layout based on their plan in order to get an exact notion in According to the specifications, a slate conveyor system with
real time for an operation that needs to be processed [17–20]. 42 assembly stations and a EMS system with correct align-
Using CAD, CAM [16], and CIM [21], digital modelling ment into QUEST was created. In this system, we primarily
makes it easier to create more advanced and complicated need to handle three conveyor, so we have constructed three
designs. This digital layout arrangement aids in the improve- zone to complete chsassis in line. However, before building
ment of operational efficiency as well as the development of sources, we have firstly created three elements in the element
more practicable, versatile, and desirable products. This aids class, i.e., Cab Body (2 × 2 × 1.5 m), Frame Load Body (11.5
in the elimination of unnecessary flow in the assembly line × 2 × 0.3 m), and Engine (1 × 1 × 0.7 m). Because this is
[22] as well as improving efficiency. In the research work, we an assembly process, a sub-resource is necessary to define
have used the Dassault System DelmiaTM QUEST® PLM the complete assembly of chassis process in line. We have
[23] software. Because Delmia QUEST® is a Dassault Sys- defined three points in the stacking table of the sub-resource
tems programme that gives a very powerful platform, with after declaring the sub-resource (2 × 1.5 × 0.05). Now we
the use of 3D experience, to help us optimize industrial opera- have constructed a new element called Chassis and link the
tions planning and management by redefining the worldwide sub-resource to it.
business. QUEST [24] stands for Queuing Event Simulation We have defined three conveyor sources in this present
Tool, one of Delmia’s branches those aids in the analysis work and placed the objects in the positions described by the
and design of any process that is or can be employed dur- design using the assembly layout design provided by the pro-
ing any industrial process. Manufacturers [25] can use this cess planning team in.cgr file that can be viewed in CATIA
to create the setup correctly in very first attempt. QUEST® V5. The hanger count on the first EMS segment of 9 station of
has allowed us to create a complex manufacturing simula- conveyor and on the second PNF segment of 20 conveyor and
tion in which we may allocate a single tool to a single or placed them on the EMS section based on a rough estimate
several purposes. Designers and process planners can ana- based on the carrier’s length and projected travel time and
lyze different processes, products, and resources by building last third conveyor of 9 station complete full chassis in run-
a virtual factory with Delmia™ QUEST® [26], which elim- ning condition. These Chassis points aid in the loading and
inates the requirement for physical prototype or mock-up for unloading of parts as well as the movement of parts from one
production tooling [27]. Manufacturers employ these tech- loading point to the next unloading point. We have defined
nologies to reduce RandD costs, off-cycle production, ramp three on the conveyor system, one EMS loading points on
up production, and shorten time to market [25] with the use of the first conveyor system, and next EMS unloading points
these tooling methods. The programme covers the planning on the second conveyor system in this project. The assem-
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International Journal on Interactive Design and Manufacturing (IJIDeM)
TT AV/DP,
3 Simulation time calculation
According to the data provided by process planner, the fac- where AV Total available time or work, DP Demand rate
tory operates in 28-h shifts. of production, and TT is the Takt time. So based on input,
As a result, the total simulation time is 8 × 60 min/shift the calculated Takt Time is 7.75 min/vehicle.
and (30 min/shift Lunch Time and 15 min/shift Breakfast).
According to the data provided by process planner, the
factory operates in 28-h shifts. As a result, the total simulation 5 Standardization of work
time is (8 × 60 min/shift—30 min Lunch—15 min Breakfast)
435 min/shift. When we migrate from BS-4 to BS-6, several The standardized work process is intended to provide the
parts, such as the exhaust system, pneumatic layout, electrical technician with the most up-to-date way for safely and effi-
layout, and urea system layout, takt time added accordingly. ciently performing the task while meeting the organization’s
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International Journal on Interactive Design and Manufacturing (IJIDeM)
S. No. Operator count Added work content (Min.) Operator loading (%) Activity description
1 OP57 5.90 91 Fuse cable and cable earthen routing and layout
2 OP58 6.02 93 Pneumatic pipes layout and connection
3 OP59 6.26 96 Pneumatic pipes layout and connection
4 OP95 5.80 89 Rear axle ABS cable connection and 4 cable tie
5 OP114 4.33 67 Differential switch harness routing, layout and
clamping at 3 positions
6 OP141 4.70 72 Front ABS connection, routing, layout and
clamping
7 OP185 5.45 84 Post inversion electrical, nylon routing, layout
and cable tie
8 OP186 5.40 83 Post inversion electrical, nylon routing, layout
and cable tie
9 OP187 4.94 76 Battery cable, fues box, connection, layout and
tieing
10 OP188 4.88 75 Battery cable, fues box, connection, layout and
tieing
11 OP191 3.60 55 Radiator side bottom bracket LH
12 OP192 3.60 55 Radiator side bottom bracket RH
13 OP198 3.90 60 Dip stick routing, clamping
14 OP225 5.80 89 Prima foot step sub-assy LH
15 OP226 5.80 89 Prima foot step sub-assy RH
16 OP229 6.60 102 Foot rest unit fitment LH
17 OP230 6.40 98 Foot rest unit fitment LH
18 OP231 6.60 102 Foot rest unit fitment RH
19 OP232 6.40 98 Foot rest unit fitment RH
20 OP233 5.60 86 Stabalizer bar connection and pin locking
21 OP234 5.60 86 Stabalizer bar connection and pin locking
22 OP261 5.60 86 Outer heat shield bracket
23 OP262 5.44 84 Outer heat shield fitment
24 OP263 8.84 136 Prima bumper sub-assy
25 OP264 7.60 117 Prima bumper sub-assy
26 OP265 10.60 163 Prima bumper sub-assy
27 OP266 6.50 100 Prima bumper fitment (estimated)
28 OP267 6.50 100 Prima bumper fitment (estimated)
29 OP268 6.50 100 Prima bumper fitment (estimated)
30 OP269 8.60 132 Aero corner sub-assy
31 OP270 8.60 132 Aero corner sub-assy
32 OP271 7.60 117 Aero corner fitment (estimated)
33 OP272 7.60 117 Aero corner fitment (estimated)
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International Journal on Interactive Design and Manufacturing (IJIDeM)
Table 1 (continued)
S. No. Operator count Added work content (Min.) Operator loading (%) Activity description
1. Takt time (Customer Demand Rate) Takt time is a term The standardized work process begins by establishing the
used to describe how long it takes for a unit must fre- present state of work (baseline) analysis for each station
quently be produced (in seconds) to match customers’ [25–29] before making any improvements and optimized
demands. parameters will be reviewed and implemented in the new
2. Operating work sequence It is defined as the operator’s or improved workstation. In this present work, there is two
sequence of actions in order to complete the task at hand. stages to be implemented in line production. The first step
The goal of this phase is to list and describe each activity, includes creating a baseline for the current situation as shown
as well as the time required to do it. Based on the defini- in Fig. 1. This baseline comprises estimating the level of
tion of each, time connected with each activity must be improvement that may be made by creating a standardized
classified into one of two categories: value added (VA) work analysis for all processes within the researched area.
or non-value added (NVA) work and or task. As we will All three conveyor with material handling system utiliza-
reduce Non value added element to improve Takt time tion improve then productivity improve. Step two involves
and improve productivity. This data will be crucial in making improvements analysis of the data collected in the
calculating each operator’s efficiency and utilization. The first stage as shown in Fig. 2. This improvement will affect
operating efficiency calculations are determined by the all stations within the specified area and/or zone, and it will
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Table 2 Statistical data of assembly process after optimization
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Unbalanced condition Balanced condition
Operator Work content Operator loading Activity description Added work New work content Operator loading Activity description
count (Min.) (%) content(Min.) (Min.) (%)
OP8 3.86 59 Base mounting 2.60 6.46 99 Base mounting bracket, 2 clamps
bracket and 1 front sensor
OP9 3.52 54 Front ARB 2.68 6.20 95 Front ARB mounting bracket LH
mounting bracket and double clamps 4 nos
LH
OP10 3.52 54 Front ARB 2.68 6.20 95 Front ARB mounting bracket RH
mounting bracket and double clamps 4 nos
RH
OP13 3.24 50 Engine mounting 2.20 5.44 84 Engine mounting bracket, rubber
bracket, rubber bush, 1 spacer plate and 1 spacer
bush LH fitment LH
OP14 3.24 50 Engine mounting 2.20 5.44 84 Engine mounting bracket, rubber
bracket, rubber bush, 1 spacer plate and 1 spacer
bush RH fitment RH
OP16 1.96 30 Centre bearing 1.88 3.84 59 Centre bearing bracket and 2 side
bracket brackets on LM and Tightening
OP22 3.18 49 Fuel tank mounting 2.28 5.46 84 Fuel tank mounting bracket, spacer
bracket plate and side bracket fitment
OP37 3.45 53 Bracket and clamps 2.80 6.25 96 Bracket and clamps fitment (9 nos)
fitment (9 nos)
OP38 3.30 51 Bracket and clamps 2.60 5.90 91 Bracket and clamps fitment (8 nos)
fitment (8 nos) and and 1 breather pipe clamping
1 breather pipe
clamping
OP39 3.45 53 Bracket and clamps 2.80 6.25 96 Bracket and clamps fitment (9 nos)
fitment (9 nos)
OP40 3.30 51 Bracket and clamps 2.60 5.90 91 Bracket and clamps fitment (7 nos)
fitment (7 nos) and and 1 breather pipe clamping
1 breather pipe
clamping
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Table 2 (continued)
Operator Work content Operator loading Activity description Added work New work content Operator loading Activity description
count (Min.) (%) content(Min.) (Min.) (%)
OP41 4.28 66 Bracket and clamps 3.34 7.62 117 Bracket and clamps fitment (11 nos)
fitment (11 nos)
OP42 3.45 53 Bracket and double 2.80 6.25 96 Bracket and double clamps fitment
clamps fitment (9 (9 nos)
nos)
OP43 3.60 55 Bracket, double and 3.20 6.80 105 Bracket, double and C fitment (10
C fitment (10 nos) nos)
OP44 2.78 43 Tilt cab mounting 2.36 5.14 79 Tilt cab mounting bracket and along
bracket and along with tilt cab circuit bracket
with tilt cab circuit
bracket
International Journal on Interactive Design and Manufacturing (IJIDeM)
OP47 4.48 69 Combo modulator 3.60 8.08 124 Combo modulator and relay valves
and relay valves fitment and 2 solenoid valve and
fitment clamps
OP50 6.40 98 Electrical wiring 3.20 9.60 148 Electrical wiring harness layout,
harness layout clamping and cable tie
OP51 5.88 90 Electrical wiring 3.20 9.08 140 Electrical wiring harness layout,
harness layout clamping and cable tie
OP52 6.24 96 Electrical wiring 3.20 9.44 145 Electrical wiring harness layout,
harness layout clamping and cable tie
OP53 5.96 92 Electrical wiring 3.20 9.16 141 Electrical wiring harness layout,
harness layout clamping and cable tie
OP54 4.48 69 Nylon bunch layout 3.60 8.08 124 Nylon bunch layout and 4 clamp and
4 cable tie
OP55 4.20 65 Nylon bunch layout 3.60 7.80 120 Nylon bunch layout and 4 clamp and
4 cable tie
OP56 3.80 58 Nylon bunch layout 3.60 7.40 114 Nylon bunch layout and 4 clamp and
4 cable tie
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Table 2 (continued)
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Unbalanced condition Balanced condition
Operator Work content Operator loading Activity description Added work New work content Operator loading Activity description
count (Min.) (%) content(Min.) (Min.) (%)
OP57 4.16 64 Nylon bunch layout 3.60 7.76 119 Nylon bunch layout and 4 clamp and
4 cable tie
OP58 4.32 66 Battery cable 1.60 5.92 91 Battery cable layout and tying
OP59 4.08 63 Battery cable 1.78 5.86 90 Battery cable layout and tying
OP77 4.40 68 AC pipe fitment 2 2.40 6.80 105 AC pipe fitment 2 nos and 4
nos clamping with brackets
OP78 4.96 76 AC Pipe Connection 1.68 6.64 102 AC Pipe connection with APU and 4
with APU clamping with brackets
OP89 4.24 65 Hydraulic pipe 1.12 5.36 82 Hydraulic pipe layout, clamping and
layout cable tie
OP90 4.10 63 Hydraulic pipe 1.12 5.22 80 Hydraulic pipe layout, clamping and
layout cable tie
OP140 2.24 34 Air tank mounting 3.24 5.48 84 Fender bracket fitment and air tank
mounting
OP141 2.10 32 Air tank fitment 3.20 5.30 82 Fender bracket fitment and air tank
fitment
OP168 5.02 77 Air filter mounting 1.20 6.22 96 Air filter mounting bracket and work
bracket lamp fitment
OP169 5.02 77 Air filter mounting 1.22 6.24 96 Air filter mounting bracket and work
bracket lamp fitment
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International Journal on Interactive Design and Manufacturing (IJIDeM)
OP8
OP9
OP140
OP141
OP168
OP169
OP10
OP13
OP14
OP16
OP22
OP37
OP38
OP39
OP40
OP41
OP42
OP43
OP44
OP47
OP50
OP51
OP52
OP53
OP54
OP55
OP56
OP57
OP58
OP59
OP77
OP78
OP89
OP90
Table 3 Overall statistical data chart of unbalanced and balanced assem- In order to make the system balanced the annalistic team
bly line identified flexible tools and equipment’s that the operators
S. No. Overall entity Unbalanced Balanced could use to reduce time for assembly and improve the pro-
cess. We have considered top four concerns before making
1 Work content 1310.91 1329.75 recommendations and modifications:
2 Added work content N/A 313.92
3 Takt time 2092.50 2092.50 1. Due to budget (cost) constraints, most improvements
4 Assigned takt time 1755 1755 regarding tools, fixtures, racks, tables, etc. had to be cre-
5 Operator count 270 311 ated in-house.
6 Operator loading 75% 83% 2. Some recommendations did not work. Due to differing
classifications, labor union contractual agreements do not
enable operators to do inspection work.
3. Limitations in floor space and repeated utilization of
employ new approaches to enhance the operational efficiency
instruments, selected non-value added work cannot be
and usage [30–33].
eliminated.
4. Number of shifts, however the team solely consists of
personnel from the first shift. The team’s recommenda-
tions were reviewed by the affected employees for all
6 Results and discussion
shifts, and various improvements were implemented to
meet their needs.
In this case study, the actual model was built at the level
of safety comfort work, so that adjustments can be imple-
mented with low-cost automation and modifications. Hence, During the unbalanced condition the total processes are
the simulation data was collected, and chart data is prepared. 270 in number while after adding 42 new work content, total
Then, modifications were performed on the existing work of 312 processes are counted, and the condition is named as
content to demonstrate the exceptional improvement in oper- balanced case. The new added processes in the old pattern
ating efficiency. Table 1 summarizes the improvements in (unbalanced condition) are depicted in Table 1, while the
operational efficiency after using the new model. A simu- Table 2 summarized the comparison of balanced and unbal-
lated model was developed at the actual level, and it was anced condition. It has been clearly observed that with the
attempted to conclude in accordance with the requirements addition of new process in terms of added work content,
of safety, productivity, and manpower reduction, among oth- there is remarkable improvement in operator loading effi-
ers. Study graphs are illustrated to show the difference in ciency. From Tables 1 and 2, It has been clearly evident that
operational efficiency when a new technique was used in adding 42 new work content, the average operator loading
conjunction with some changes to the existing work content. has been increases. Similarly, after assessing the unbalanced
This easy graphing technique can be used by team leaders condition, new work content has been added which leads
to analyze cycle times and eliminate idle and overburden- towards the improvement in operator loading. For instance,
ing workstations. This solution decreases non-value-added in unbalanced condition, the operator loading of are 59%,
work wastage, standardizes line balancing, and lowers prod- 54% and 54% at OP 8, OP 9 and OP 10, respectively while
uct costs through improved production. in case of balanced condition, it was found to be increased
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International Journal on Interactive Design and Manufacturing (IJIDeM)
to 99%, 95% and 95%, respectively. In balanced condition analysis in Fig. 3, which represents the unbalance condition
2 clamps and 1 front sensor added into the OP 8, Double while contained the processes of balanced condition.
Clamps 4 (nos) added into the OP 9 and Double Clamps 4
(nos) is added into the OP 10. This one step improvement
was able to improve operation efficiency by 40%, 41% and
41% in OP 8, OP 9 and OP 10, respectively, therefore, giving 7 Unbalanced condition analysis
the operator more time in order to take on additional work
or improve the overall efficiency. Maximum improvement A current baseline standardized work analysis was estab-
in the operator efficiency was found as 56% in case of OP lished. The standardized data was estimated by observing
56 while the minimum improvement was noticed as 19% in actual operators and taking data that included job dura-
case of OP 168 as well as OP169. For OP 56, the operator tion and workstation space. The information gathered was
efficiency was found as 58% in case of unbalanced condition depicted in the standardized data that were created and pro-
while 114% during balanced condition. The improvement vided in Table 2. A work content time was added based on
of 56% was noticed after adding new work content (4 clamp the information obtained from the current standardized work
and 4 cable) into the existing work (Nylon bunch layout). The analysis. Table 3 shows statistical analysis chart that was
processes difference has also been shown in the comparative developed. Results in the form of operator loading is deter-
mined form the unbalanced condition:
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International Journal on Interactive Design and Manufacturing (IJIDeM)
1. Average overall efficiency is 75%. 3. New tools have been made available that can help with
2. Average available time is 1310.91 min, with an opportu- speedier response times and injury reduction.
nity for improvement (OFI).
3. The average observed time is more than the assigned
In order to check the errors, simulation work has been done
time, and various processes are running more than 30% of
by taking unbalanced condition as the basic entity. Through
the time outside of assigned takt time, which is depicted
individual part inspection, errors have been clearly identified
in Fig. 4.
and proper precautions has been taken care with respect to
these errors as shown in Fig. 5.
As a result, Average overall efficiency was increased to
83% as compared to unbalanced condition. Most of the activ-
8 Balanced condition analysis ities took very less time to complete, which is very helpful
for rapid and mass production. This saves a lot of time and
It demonstrates the methods used to increase operating effi- money, which has a direct or indirect impact on manufac-
ciency at various stations. The main goal was to optimize turing costs. By increasing or decreasing the speed of the
each station to achieve the highest operating efficiency, men- element, QUEST simulation data will assist in accommo-
tioned below: dating the conveyor system. This will help to increase the
system’s efficiency depending on the processer planner’s or
1. Recommending and implementing a new, "more" effi- production requirements. The proposed assembly line could
cient method for completing a task aid in the modification of the assembly order of various parts.
2. To improve efficiency and usage, material, tools, parts, This sequence can be readily defined on the system, and the
and fittings were transferred to new locations or placed simulation can be run with minor or significant changes. The
in other containers. use of a conveyor is highly necessary at regular intervals.
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