Production capacity analysis of a shock absorber assembly line using simulation

This paper reports findings of a study of shock absorber assembly line using computer simulation. The shock absorber assembly line feeds shockers to the motorcycle assembly line. The assembly line simulated in this project is located at an OEM for Bajaj Auto Ltd., the largest producers of scooters and motorcycles in India. In this paper, results of simulation are presented from two scenarios. The first is the original layout of the system. The second simulation is the suggested modifications. Data was gathered and evaluated to determine the necessary parameters to be used. The new demand required the OEM to increase its capacity by 200 shock absorbers per day. After implementing the proposed model the daily output increased by 435 shock absorbers. The highlights of our analysis was that this increase in production rate was achieved without any increase in direct labor, contributing to a gross increase in profit by 32%.