Automation of welding processes of a subcomponent of the tubular motorcycle chassis in a company from the Manaus Industrial Hub

Abstract

One of the fundamental requirements to ensure the sustainability and survival of a company is to have a production planning system that establishes lean processes, is adaptable to change, and efficient enough to guarantee productivity, quality, and financial returns from industrial operations. In this regard, process automation becomes an essential activity within a company’s strategic plan, as it promotes competitiveness based on new Industry 4.0 technologies. Accordingly, this study describes the development and implementation of automated welding processes for motorcycle chassis in a two-wheeler manufacturing company located in the Industrial Hub of Manaus, Brazil. The implementation of automation in the production line was carried out in phases, with the first phase focused on the production of the rear subcomponent of the chassis, which is the object of this study. This initial stage was chosen due to difficulties in meeting the daily production plan, which was operating 12% below what was required capacity for the main line. The study considered the collection of key performance indicators focusing on production plan data, process times, and workforce numbers, as well as time and motion studies to validate the automation proposal through computer simulation. The results of the proposed automation aimed to optimize the production of this subcomponent by 20% above the current demand, increasing the production capacity from 960 to 1,152 units per day for the main line, while requiring fewer labor resources and highlighting the strategic importance of time analysis and simulation tools in process definition.