Modelling and Optimization of Organization of Workplaces in a Foundry

Abstract

Abstract The paper presents a practical example of improvement of foundry production systems in terms of post-finishing of nodular iron castings produced in the conditions of bulk production for automotive industry. The attention was paid to high labour-intensive efforts, which are difficult to be subjected to mechanization and automation. The times of actions related to grinding processing of castings in three grinding positions connected with a belt conveyor were estimated with the use of a time study method. A bottleneck as well as limiting factors were specified in a system. A number of improvements were proposed, aimed at improving work organization on the castings post-finishing line. An analysis of work ergonomics at the workplace was made in order to eliminate unnecessary and onerous for the employee actions. A model of production system using the Arena software, on which a simulation experiment was conducted, was drawn up in order to visualize the analysed phenomena. The effects of the project were shown on graphs comparing times, costs, work ergonomics and overall efficiency of production equipment indicator.