Resource optimisation for an automobile chassis manufacturer through value stream mapping enhanced with simulation technique and constraint programming

Incorporation of lean thinking has become an essential part of any manufacturing system, as reducing waste leads to cost savings and hence competitiveness of the company. Value stream mapping (VSM) which leads to cost savings is a part of the portfolio of tools to achieve lean orientation in manufacturing systems. Lean implementation starts with the application of VSM to an assembly line; however, it has various limitations. VSM being a pencil-and-paper technique is a static tool. It does not provide a dynamic view of the situation. There is need to enhance the VSM through discrete-event simulation (DES) technique (using Arena® simulation software) and constraint programming (using CPLEX® optimisation software) for an assembly line balancing problem (ALBP). This study suggests the usage of a simulation tool to gain meaningful insight into an assembly line to minimise waste. Constraint programming using combinatorial optimisation helps in efficient resource planning of an automotive chassis assembly line. Although the primary focus of this paper is manpower optimisation, but methodology discussed in this paper can be used for optimisation of machine resources as well. This study is expected to enhance the lean optimisation of the assembly lines.