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Development framework of assembly line simulation and optimization for special purpose vehicle / Ahmad Shah Hizam Md Yasir

By:

Ahmad Shah Hizam Md Yasir [author.]

Material type: Text

text

Media type:

unmediated

Carrier type:

volume

ISBN:

THE0009210(Local)

Subject(s):

Dissertation note: Thesis (Doctor of Philosophy) -- Universiti Malaysia Pahang – 2021 Abstract: Defence automotive vehicle, also known as a special purpose vehicle (SPV) is a highly fabricated type of vehicle. Many research have focused on commercial vehicle production system rather than the manufacturing of special purpose vehicle. Due to that, there is lesser specific study focused on optimised solution for special purpose vehicle manufacturing. This research focuses on the performance of an existing production line for Malaysia's defence automotive manufacturing industry. The main issues that arise from observation and data collections are; firstly, delivery is always behind schedule and secondly, the human factor that contributes to the increase of rejected parts and slowdown of the production line. As such, this research aims to develop a new framework which can optimise the production efficiency for the armoured vehicle assembly line. In the present work, this study has been executed into several stages. Firstly, performs correlated data gathering in an industrial premise and develops the simulation procedure. Secondly, analysis of current production layout by using WITNESS and workers working posture using DELMIA simulation have been done. The simulation data was verified by comparing it with the actual industrial data. Then, by using systematic layout planning (SLP), the alternatives layout was proposed. Next, assembly line balancing was performed using Kilbridge and Wester method to the chosen layout. By utilising evaluation of line balancing equations, results show that the proposed layout improved line balance efficiency from 35% to 99%, balance delay from 0.65 to 0.01, and smoothness index from 115.7 to 1.82. In the third stage, the chosen alternative layout was analysed using WITNESS simulation. The result shows the production output increasing between 23% to 75% in the range from 3 to 24-month production simulation. The workers working condition was measured using DELMIA simulation following which an improvement was made in actual working conditions. Rapid upper limb assessment (RULA) shows that the improved working postures are acceptable with a score between 1 and 2. The result was validated using Ovako working analysis system (OWAS). In the final stage, by utilising both simulation techniques, a framework was developed. The proposed framework was validated by 5 experts chosen from various automotive industries background. The suggested framework may empower in the growth of total output in a manufacturing system, especially in special purpose vehicle manufacturing.

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Holdings ( 2 )
Title notes ( 4 )

Holdings
Item type	Current library	Collection	Call number	Copy number	Status	Date due	Barcode
Restricted Collection	UMPLIB PEKAN	Reference	CD 13003 (Browse shelf(Opens below))	1	Not for loan (Restricted access)		T000001675
Restricted Collection	UMPLIB PEKAN Reference	Reference	KK .S53 2021 r Thesis (Browse shelf(Opens below))	1	Not for loan (Restricted access)		T000001674

College of Engineering

Thesis (Doctor of Philosophy) -- Universiti Malaysia Pahang – 2021

Includes bibliographical references

Defence automotive vehicle, also known as a special purpose vehicle (SPV) is a highly fabricated type of vehicle. Many research have focused on commercial vehicle production system rather than the manufacturing of special purpose vehicle. Due to that, there is lesser specific study focused on optimised solution for special purpose vehicle manufacturing. This research focuses on the performance of an existing production line for Malaysia's defence automotive manufacturing industry. The main issues that arise from observation and data collections are; firstly, delivery is always behind schedule and secondly, the human factor that contributes to the increase of rejected parts and slowdown of the production line. As such, this research aims to develop a new framework which can optimise the production efficiency for the armoured vehicle assembly line. In the present work, this study has been executed into several stages. Firstly, performs correlated data gathering in an industrial premise and develops the simulation procedure. Secondly, analysis of current production layout by using WITNESS and workers working posture using DELMIA simulation have been done. The simulation data was verified by comparing it with the actual industrial data. Then, by using systematic layout planning (SLP), the alternatives layout was proposed. Next, assembly line balancing was performed using Kilbridge and Wester method to the chosen layout. By utilising evaluation of line balancing equations, results show that the proposed layout improved line balance efficiency from 35% to 99%, balance delay from 0.65 to 0.01, and smoothness index from 115.7 to 1.82. In the third stage, the chosen alternative layout was analysed using WITNESS simulation. The result shows the production output increasing between 23% to 75% in the range from 3 to 24-month production simulation. The workers working condition was measured using DELMIA simulation following which an improvement was made in actual working conditions. Rapid upper limb assessment (RULA) shows that the improved working postures are acceptable with a score between 1 and 2. The result was validated using Ovako working analysis system (OWAS). In the final stage, by utilising both simulation techniques, a framework was developed. The proposed framework was validated by 5 experts chosen from various automotive industries background. The suggested framework may empower in the growth of total output in a manufacturing system, especially in special purpose vehicle manufacturing.