CHAPTER 4

COLLECTED DATAS

4.1 FLOW CHART FOR ENGINE LINE ASSEMBLY

Sl.no.

Work

Standard Actual required time

(mins)

Quality Control

134

Engine 1 Assembly

112

Engine 2 Assembly

118

Engine Testing

26

Painting Shop

14

Finishing

58

Smoke Testing & Oil Testing

20

CHAPTER 5
TIME ANALYSIS

In KAMCO,engine assembling & testing is a repetitive work.

According to Taylor,time study is that which involves a careful study of time in
which work ought to be done.It consists of 3 factors.
1.Time taken by the workers.
2.Levelling factor for normal time.
3.Statistical principle of randomness.

5.1 CALCULATIONS TO IMPROVE EFFICIENCY OF ENGINE

TESTING

Factory working time 8 hrs(480 min)

Lunch & tea breaks(30+15+15)- 60 min

Actual working time 480 60= 420 min

Time reqd for testing one engine= 26.32 min

Add allowance = 3.68 min

Total = 30 min

Hence no. of engines within one day= 420/30

=14 nos

 No. of engines tested actually observed=9 nos

Time wastage noticed = 420-(9*30)
= 150 min
As such 5 no. of engines testing can be increased by proper
control & using time analysis.

CHAPTER 6
SIMULATION USING ARENA
The simulation model of the traditional assembly system was used as the basis to
initiate the design phase. Various modifications were assessed using the model. Some of
these are:
- Balanced lines.
- Degree of multi-functionality.
- Various changes in the work station layouts.
- Modifications in activities sequencing.
-Changes in product mix assembled in each line.

6.1 SIMULATION
Simulation refers to a broad collection of methods and applications to mimic
the behavior of real systems, usually on a computer with appropriate software. In fact,simul
tion can be an extremely general term since the idea applies across many fields,industries,
and applications. These days, simulation is more popular and powerful thanever since
computers and software are better than ever.
Computer simulation refers to methods for studying a wide variety of models of realworld systems by numerical evaluation using software designed to imitate the
systemsoperations or characteristics, often over time. From a practical viewpoint, simulation
isthe process of designing and creating a computerized model of a real or proposed systemfor
the purpose of conducting numerical experiments to give us a better understanding of the
behavior of that system for a given set of conditions. Although it can be used to studysimple
systems, the real power of this technique is fully realized when we use it to studycomplex
systems.While simulation may not be the only tool you could use to study the model,
itsfrequently the method of choice. The reason for this is that the simulation model can
beallowed to become quite complex, if needed to represent the system faithfully, and youcan
still do a simulation analysis. Other methods may require stronger simplifyingassumptions
about the system to enable an analysis, which might bring the validity of themodel into
question.

6.1.1 S I M U L A T I O N L A N G U A G E S
Special-purpose simulation languages like GPSS, Sim script, SLAM, and SIMAN
appeared on the scene some time later and provided a much better framework for the kinds of
simulations many people do. Simulation languages became very popular and are still in
use. Nonetheless, you still have to invest quite a bit of time to learn about their features and
how to use them effectively. And, depending on the user interface provided, there
can be picky, apparently arbitrary, and certainly frustrating syntactical idiosyncrasies that bed
evil even old hands.

6.2 SIMULATION USING ARENA

Arena combines the ease of use found in high-level simulators with the flexibility
of simulation languages and even all the way down to general-purpose procedurallanguages
like the Microsoft Visual Basic programming system or C if you reallywant. It does this by
providing alternative and interchangeable templates of graphical simulation modeling and
analysis modules that you can combine to build a fairly widevariety of simulation models.
For ease of display and organization, modules are typicallygrouped into panels to compose a
template. By switching panels, you gain access to awhole different set of simulation
modeling constructs and capabilities. In most cases,modules from different panels can
be mixed together in the same model.Arena maintains its modeling flexibility by being fully
hierarchical as depicted. At any time, you can pull in low-level modules from the Blocks and
Elements panel and gain access to simulationlanguage flexibility if you need to and mix inSI
MAN constructs together with the higher level modules from other templates (Arenais based
on, and actually includes, the SIMAN simulation language; see Pedgen,Shannon, and
Sadowski 1995 for a complete discussion of SIMAN). For specialized needs, like complex
decision algorithms or accessing data from an external application,you can write pieces
of your model in a procedural language like Visual Basic or C/C++.All of this, regardless of
how high or low you want to go in the hierarchy, takes place inthe same consistent graphical
user interface.