Abstract
In Pakistan, automotive sector is setting leaps in term of expansion, and achieved a phenomenal growth of 171% between the years 2014 and 2018. Keeping in view, the high demand and production of the sector, it is crucial to generate fruitful revenue from it. For this purpose, the production lines efficiency and productivity should be significantly optimized. Nowadays majority of industries are shifting towards green manufacturing with the application of lean manufacturing tools such as implementation of Takt Time. The proposed study is carried out at Honda Pakistan to reduce the cycle time of KIRA machine through line balancing techniques (Largest Candidate Rule, Longest-Task-Time Heuristic and Mathematical Modelling), capacity calculation, and validated the results via Rockwell Arena simulation software. Moreover, cost benefit analysis is committed to check economic effect of proposed model. Further, after implementation of proposed model, the cycle time of KIRA is reduced from 68.8 sec to 59.08 sec (takt time), and production rate is enhanced from 2800 parts to 3263 parts per day. Lastly, bottleneck is resolved, ultimately leading to increase in line efficiency and station utilization, while on other hand balance delay and line smoothing index are decreased.