Material Optimization and process improvement using simulation for makeshift auto chassis manufacturing of an Indian SME

Makeshift manufacturing approach can be characterized by unorganized process flow, improper layout and inadequate planning. Most of the SMEs in India adapt this approach for manufacturing their products. In this study one instance of a three wheeler (auto) manufacturing company named XYZ Auto is under study. For any auto manufacturing, chassis is a major part. In this paper, micro level studies of chassis manufacturing are done by means of time and motion study .The process flow is modelled using ARENA simulation software to analyze the impact of alteration in the model. Concepts of cutting stock problem are utilized for Material Optimization. Simulation modelling helps in identifying the bottleneck process and analyzing the effect of changes in processing times by changing the process flow without adding any new machine or resource.