IMPROVISATION OF MATERIAL HANDLING ACTIVITIES FOR CONTINUOUS CONVEYOR MIXED MODEL ASSEMBLY LINE

The project work exclusively focuses on improving the material handling activities for the continuous conveyor mixed model assembly line (MMAL).The material handling includes activities ranging from issuing of purchase orders to issue of material at point of use. The forklift movement which is a parameter of high priority is taken into consideration with respect to the mixed model assembly line. The main objective is to reduce the forklift movement and also the transit delay that occurs between point of storage to point of use. The zig zag movement of fork lift within warehouse is a major cause for delay in feeding the items to MMAL. Some purchasing policies with respect to bottleneck items are taken into consideration in order to improve their movement. The usage pattern of materials is not taken into consideration in present storage layout, which results in shifting the items from large distances. The warehouse is used not only for storing items for MMAL but also for storing items needed for individual assembly lines. This occupies more space in the warehouse. Many of the items which are non-moving, not at all moving (due to change of design) are also stored in warehouse. The methodology implemented to reduce the fork lift movement is done by replacing the fork lifts by tow-trucks. The Kraljic purchasing portfolio model and also the Porters Five forces model have enabled to reduce the risk of delays associated with bottleneck items(high supplier's risk, low profit impact). So for the firm, one of the goals ie, converting the bottleneck items into leverage items is slowly progressing. The imports storage area which is near to individual assembly line but away from MMAL is redesigned(using Solidworks) for storage of items which exclusively focuses on individual assembly lines and not on MMAL. After the implementation of proposals the fork lift movement is likely to be reduced and results in savings of distances travelled from 14764 m to 7639 m, and diesel consumption by 49%. Also the working hours of forklift operators in second shift is avoided. The main warehouse is redesigned to focus only for MMAL so that the problem of shortage of items in kits is eliminated. This approach has removed many non-moving items from warehouse and made the kit making process easier by saving time. The Kraljic model has classified the items in four different categories, so that the bottleneck items are highly prioritized and their risk of non-availability in assembly line reduces. The conversion of open area (imports) to mini warehouse has improved the utilization of huge storage area to hundred percent. The surrounding areas around MMAL are fully utilized to 100% which was 55% earlier. So that the items are stored properly and fed on time according to their usage.