In the heart of Thailand, a manufacturing company producing agricultural machinery parts faced a daunting challenge: it couldn’t keep up with customer demand. The company’s daily production of 280 units lagged behind the required 350 units, a gap that threatened to leave farmers waiting for essential equipment. But a recent case study published in the RMUTL Engineering Journal offers a beacon of hope, demonstrating how innovative engineering solutions can revitalize production lines and bolster the agriculture sector.
The study, led by Bhoomboon Phontang from the Faculty of Engineering and Technology at Rajamangala University of Technology Isan, delved into the company’s production process, identifying bottlenecks and inefficiencies. The researchers employed a suite of engineering principles, including 7 QC Tools and Failure Mode and Effects Analysis (FMEA), to pinpoint the root causes of the slowdowns.
One of the key solutions involved the implementation of a new Jig Fixture, a device used to hold workpieces during machining. “The new fixture significantly reduced the time and effort required to position and secure the workpieces,” Phontang explained. This, combined with the principles of karakuri kaizen—a Japanese method of low-cost, no-power automation—led to substantial improvements.
The results were impressive. The cycle time per unit decreased from 96.22 seconds to 75.52 seconds, allowing the company to produce 362 units daily, surpassing the initial demand. The total production distance was also reduced from 30.2 meters to 27.7 meters, further streamlining the process.
The commercial impacts of this research are profound. For the agriculture sector, this means faster production of essential machinery parts, reducing downtime for farmers and improving overall productivity. As Phontang noted, “This study demonstrates the potential of engineering solutions to address real-world challenges in the manufacturing sector, particularly in agriculture.”
The implications of this research extend beyond the immediate case study. By showcasing the effectiveness of Jig Fixtures and karakuri kaizen, the study opens doors for similar improvements in other manufacturing processes. It highlights the importance of continuous innovation and adaptation in meeting the evolving demands of the agriculture sector.
As the world grapples with the challenges of feeding a growing population, such advancements in agricultural machinery production become increasingly vital. This research not only addresses a specific production bottleneck but also sets a precedent for future developments in the field, paving the way for more efficient, cost-effective, and sustainable manufacturing practices.