Optimization of Scorpio front suspension (W105) assembly line by using ECRS Principles

Abstract: In today's competitive manufacturing environment, companies are constantly looking for ways to improve in their production process. A new flow of assembly line is proposed for suspension assembly line. An assembly line of a Front Suspension of Mahindra Scorpio is to be optimized to increase the productivity. This paper presents the improvement of production rate and balance loss ratio of the manual assembly line. Using ECRS four principles (Eliminate, Combine, Rearrange and Simplify) minimize the idle time or the percentage of line balance loss. The result shows that cycle time of the assembly line is reduced from 56 seconds to 48 seconds and Production rate increased from 250 to 293 pieces per hour. Keywords: Assemble line, ECRS, work-study, balancing, optimization.