Assembly line layout and process optimization at Powertech Transformers

Abstract

Powertech Transformers, located in Pretoria West, is one of the largest and sophisticated transformer manufacturing plants in the southern hemisphere. The variety of products manufactured is used by local authorities, mines, industrial plants, and the utility industry. The manufacturing plant has experienced problems with the productivity and efficiency of their active assembly area. This project was aimed at optimizing the active assembly line layout and at improving the current process. The selection and implementation of the relevant industrial engineering tools and problem solving techniques helped to achieve this goal. This document describes the situation at Powertech Transformers and how the implementation of systematic layout planning and lean manufacturing will achieve potential savings and improvements. These selected techniques have been directed at improving specifically the material flow and tool usage to ultimately optimize the efficiency and production effectiveness throughout the overall layout area. The future state of Powertech Transformers has a more efficient flow of materials and operations and will ultimately improve the productivity of the area. The improvements will enable the operators and management to have more control over the process and to focus their attention on the quality of the operations and the products. It is expected that with more focus on quality that less products will be faulty, saving time and money.