Throughput Rate Improvement in a Multiproduct Assembly Line Using Lean and Simulation Modeling and Analysis

It has been a real challenge to improve the throughput of multiproduct assembly lines due to the complexity of the multiproduct assembly processes. In this paper, we used pull simulation module to mimic a real engine assembly line where 114 different products are being assembled. Line balancing and controlling the work in process (WIP) were found to be the driving elements to improve the throughput rate. Developing effective design of experiments for the simulation modelling and analysis helped in validating the impact of the changes. Recommended solutions have helped the engine assembly line to increase its throughput rate by 14%.