Productivity Measurement and Improvement in Manufacturing Firms by Improving Assembly Line

The paper deals with case study for improving production efficiency of one off manufacturing firm, which have been providing quality sheet metal Air Coolers to the customers, but still it suffers from lack of effective Plant layout, and has improper sequencing of processes. Thus there is wide scope of improvement for enhancing the productivity. Hence to remove the flaws the study of processes is done that are involved in manufacturing and assembly of parts of coolers. The need of this study is streamlining of processes and proposing the changes in the present process to standardize operations and design.The work deals with the study of steps involved in manufacturing of each part, which helps to get design of parts and designing Process Flow Diagram. From the Process Flow Diagram, Standard Operating Procedure can be obtained. The operators are performing the operations according to their estimation, but now the SOP will help them to follow the particular sequence of steps. Various parameters and machines used are studied. The study helps to identify manual and machinery operations.The work involve the use of AUTOCAD software of two dimensional drawings of parts.The study deals with designing the present plant layout and obtaining the new plant layout by the proposing changes to improve productivity. The present plant layout needed to be changed because it cause blocking of operation . Operation are not able to perform various operations simultaneously. Also the process have become complex and timing consuming.The modified plant layout gives proper sequence of process.According to the study the four different variants of coolers available and founded their dimensions. Indentification that there is no standardization for the process has been made.The operators are unable to keep the dimensions contant in all the parts for the different coolers of the same model.Moreover, for different model the dimensions of all the parts varies with the other models.Obeservation that within different models only the size of fan and so the size of front called a circle should vary ,keeping the dimensions of all the other parts as constant within all the models has been made.this can reduce the unnecessary utilization of sheet metal and thus saves time and enhance the productivity.Based on all the observations changes were proposed to improve productivity.The AS-IS and TO-BE Analysis is performed,which includes transformation of processes as it is performed today towards a new processes that addresses problems with AS-IS analysis. The present research focuses on measuring and improving productivity in manufacturing firms through a structured approach. The study adopts a systematic methodology, including the identification of productivity indices, data collection from selected firms, and analysis using performance ratios. The productivity measures considered include labor productivity, machine productivity, material productivity, and rejection rates. These indices help identify existing inefficiencies and provide quantitative insights into resource utilization.