A GREEN SOLUTION FOR PRODUCTION EFFICIENCY: KARAKURI-INSPIRED SUPPLY TROLLEY DESIGN AND ANALYSIS

Abstract

The delivery of product parts during assembly is a critical factor that significantly influences the overall efficiency and effectiveness of manufacturing operations. Inefficiencies in part transfer processes—particularly excessive movement and delays between platforms—can lead to increased operational costs, reduced productivity, and heightened physical strain on workers. Addressing these issues, this study presents a green and sustainable solution through the design and analysis of a Karakuri-inspired supply trolley aimed at optimizing part delivery within assembly areas. The proposed trolley leverages gravity and simple mechanical linkages to operate without needing electrical or pneumatic systems, thereby reducing energy consumption and maintenance requirements. The design process encompasses concept development, modelling of essential features, and thorough performance evaluation using working cycle analysis. CAD modelling and physical prototype testing were employed to validate the design’s functionality and potential contribution to lean manufacturing practices. Results demonstrate that the Karakuri-inspired trolley effectively reduces unnecessary motion and streamlines material flow, contributing to a notable reduction in production cycle time. In addition to enhancing workflow efficiency, the design also minimizes worker fatigue, supports ergonomic improvements, and aligns with sustainability goals by minimizing environmental impact. The integration of this trolley into production lines has the potential to elevate part handling efficiency while promoting consistent production quality.