Industrial engineering is a branch of engineering that deals with the optimization of complex systems, processes, and organizations. The goal of industrial engineering is to increase efficiency, productivity, and profitability while minimizing waste, costs, and resources. To achieve this goal, industrial engineers use a variety of tools and techniques, including mathematical models, simulation, optimization, quality control, and project management. In this technical capstone paper, we will discuss a case study of a manufacturing company that faced a production problem and used industrial engineering techniques to solve it.
Case Study
The manufacturing company in question is a medium-sized firm that produces electronic devices. The company had been experiencing a problem with its production line, which was causing delays, quality issues, and increased costs. The problem was that the production line was not balanced, which meant that some stations were overburdened while others were idle. This imbalance was causing bottlenecks, backlogs, and defects, which were affecting the overall efficiency and profitability of the company.
To address this problem, the company hired a team of industrial engineers to analyze the production line and propose solutions. The team consisted of four engineers who had expertise in production planning, process design, quality control, and project management. The team members worked together to conduct a thorough analysis of the production line, using data from the company’s records, observations, and interviews with the workers.
The first step in the analysis was to map the production line and identify the different stations, processes, and tasks involved in the manufacturing process. The team used flowcharts, process maps, and value stream maps to visualize the production line and identify the areas of improvement. They also collected data on the cycle times, lead times, and throughput of each station to quantify the performance of the production line.
The next step was to identify the bottlenecks and imbalances in the production line. The team used simulation models and mathematical models to analyze the flow of materials, goods, and information in the production line and identify the areas that were causing delays and overburdening. They also analyzed the capacity of each station and compared it to the demand for each product to identify the areas of underutilization and overutilization.
Based on the analysis, the team proposed several solutions to balance the production line and improve its efficiency. These solutions included:
Redesigning the layout of the production line to reduce the distance and time between the stations and eliminate unnecessary movements and transportation.
Reducing the cycle time of the bottleneck stations by improving the process design, equipment, and tools used in these stations.
Increasing the capacity of the underutilized stations by cross-training the workers and adding more tasks to their workload.
Implementing a just-in-time (JIT) system to reduce inventory and lead times and improve the flow of materials and goods.
Implementing a quality control system to detect and prevent defects and reduce rework and scrap.
The team also developed a project plan to implement these solutions and monitor their effectiveness. The plan included a timeline, budget, resources, and milestones for each solution and a contingency plan to address any unexpected issues or delays.
Results
After implementing the solutions proposed by the team, the production line of the company showed significant improvements. The cycle time of the bottleneck stations was reduced by 30%, and their utilization increased by 20%. The underutilized stations’ capacity increased by 50%, and their lead times decreased by 40%. The inventory levels were reduced by 60%, and the defects were reduced by 70%. The overall efficiency of the production line increased by 40%, and the profitability of the company increased by 20%.
This case study shows how industrial engineering techniques can be used to solve production problems and improve the efficiency and profitability of a manufacturing company. By analyzing the production line, identifying the bottlenecks and imbalances, and proposing solutions, the team of industrial engineers was able to achieve significant improvements in the company’s performance. This case study also highlights the importance of project management, teamwork, and communication in implementing these solutions and monitoring their effectiveness. Industrial engineering is a valuable field that can help companies optimize their processes, reduce costs, and increase competitiveness in today’s global market.
