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The current industry demands high productivity removing every constraint inherited during manufacturing a product with limited resources. Reconfigurability and Flexibility to produce multiple components depending on customer demand is a key factor. This projects aims at optimizing the productivity of a discrete heavy duty manufacturing company which adopts a Fixed-Worker-Assembly-Line (FWAL) to manufacture multiple products. The dynamic nature of heavy duty manufacturing assembly line is improved by converting FWAL into a Walking-Worker-Assembly-Line (WWAL). The productivity of proposed WWAL is calculated using ProModel simulation software and compared with FWAL to ensure optimization. Better utilization of resources and reduction of WIP is carried out in WWAL in order to generate an optimized and dynamic manufacturing unit and establish a common set of rules in converting a FWAL into WWAL.

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A case study on implementation of walking worker assembly line to improve productivity and utilisation of resources in a heavy duty manufacturing industry