Development and Simulation Via Flexsim for Kitting Trolley Design of Rear Car Seat Assembly Process

Nursalbiah Nasir; Ahmad Fikri Sarimi; Helmi Rashid; Nurul Atikah Azis

doi:10.24191/jaeds.v3i2.70

Authors

Nursalbiah Nasir School of Engineering, Universiti Teknologi MARA, Shah Alam 40450 Selangor, Malaysia
Ahmad Fikri Sarimi School of Engineering, Universiti Teknologi MARA, Shah Alam 40450 Selangor, Malaysia
Helmi Rashid School of Engineering, Universiti Teknologi MARA, Shah Alam 40450 Selangor, Malaysia
Nurul Atikah Azis Adient Automotive Seating (M) Sdn Bhd, Selangor, Malaysia

DOI:

https://doi.org/10.24191/jaeds.v3i2.70

Keywords:

kitting, productivity, CAE, Flexsim

Abstract

It was discovered that the material retrieval system used for a Sweden brand car seats assembly lines (RB40% and RM60%) in a local seat assembly company was not systematic in its arrangement of the assembly parts and only had a rack trolley that carried all the assembly parts in a poly-box. The workers had to waste time to pre kit the parts prior to assembly process thus could not meet production target. Although kitting trolleys implementation was generally known to help pre-kit earlier at logistic/warehouse department, the fabrication cost and long-term benefit would be affecting company decision to implement kitting trolley in the production line. The study aims to validate kitting trolley implementation efficiency prior to trolley actual fabrication by computer aided
simulation. Project started from feasibility study of existing kitting rack trolley in market to conceptual design to detailed design and simulation analysis. Detailed design of the kitting trolley was produced and from the design, time study showed that assembly process per carseat was reduced. Flexsim kitting trolley simulation predicted that the number of car seats produced per day is higher than production quantity target (24 seats per day) for RB40% but still below production target for RB60%. Nonetheless, both showed improvement of hence improving of quantities hence increase company’s productivity and eliminate waste of time.

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