Improving the Productivity of Pump Modules Assembly Line for Automotive Industry

From the current situation, the electric car business in Europe is growing higher which resulted in the relocation of the production base for internal combustion vehicles making it more likely into Asia. This has led to the competitive cost of the internal combustion engine automotive parts manufacturing industry. The purpose of this research is cost reduction and improve the productivity of the pump modules assembly line. The assembly line has 9 employees and 109 types of pump modules. This is a study especially the change of production model by more than 80%. The time limit for each model change is 63 seconds per time, from 2HX-GAS to 2HU, which took 140 seconds per time. Therefore analyzing the cause of the problem, and using the fishbone diagram and ORiN program found most of the production costs are incurred using manpower, changing the model of the part, including the steps in the production process some activities cause waste (Muda). The organizer has proposed a solution to the problem, which is the basic principles of ECRS, production line balancing using changing the sequence of operations and Kaizen. From switching the sequence of employee operations, there is still time wasted occurring in the production process, such as the employee's walking. Therefore, keep the jig under the employee's machine to reduce walking time, and pick up the jig at stored.