scholarly journals To study and analyze a production line of steering

Author(s):  
Ankush . ◽  
Amit Kumar

Project has been completed in the practical environment of an auto ancillary company. There is always a room for improvement in any process; the approach for study and further improvement of process is used for the fulfilment of this project. Main purpose of this project is to scrutinize every aspect of a frame line. Main focus is to study its cycle time and various wastes which can be removed from the process in order to optimize the process. Line balancing concept is used for balancing the line to get single piece flow.

2016 ◽  
Vol 15 (2) ◽  
pp. 182
Author(s):  
SAIFUL .. ◽  
MULYADI HAMBALI ◽  
TRI MUHADI RAHMAN

PT XYZ merupakan salah satu perusahaan yang bergerak di bidang industri mebel. Masalah yang dihadapi perusahaan adalah adanya ketidakseimbangan di lintasan produksi akibat ketidakmerataan pembagian beban kerja di setiap stasiun kerja. Hal ini menyebabkan performansi keseimbangan lintasan (line performance) menjadi kurang baik. Untuk menyelesaikan permasalahan ini perlu dilakukan penyeimbangan lintasan produksi. Hal ini dapat dilakukan dengan metode line balancing yaitu metode penugasan sejumlah pekerjaan yang saling berkaitan dalam satu lintasan produksi sehingga setiap stasiun kerja memiliki waktu yang tidak melebihi waktu siklus dari stasiun kerja tersebut. Metode line balancing yang digunakan adalah metode heuristik yang terdiri dari: metode bobot posisi (Ranked Positional Weight), metode pembebanan berurut (Large Candidate Rule), dan metode pendekatan wilayah (Region Approach). Dari ketiga metode Heuristik yang digunakan sebagai solusi penyeimbangan lintasan, terjadi perbaikan performansi dengan nilai yang sama pada lintasan produksi. Nilai efisiensi lintasan (line efficiency) meningkat menjadi 94,07 % dari 62,71 % pada kondisi awal. Nilai keseimbangan waktu senggang (balance delay) turun menjadi 5,92 % dari 37,28 % pada kondisi awal. Waktu menganggur (idle time) turun menjadi 12,39 menit dari 116,87 menit pada kondisi awal. Nilai smoothness index juga turun menjadi 7,44 dari 64,67 pada kondisi awal. PT XYZ is one of the company which refers to furniture industries sector. The problem which faced by this company is unbalance of the production line which is caused by the unequal of work responsibility distribution in each work station. This problem caused the performance of line balance doesn’t work properly. To solve this problem we need to do the line balancing of production line. It can be done by line balancing methode that assigns a number of work which is related in one production line until each work station has efficient time which is not more than the cycle time of the work station. Line balancing methode that used is heuristic methode which is devided into ranked positional weight methode, large candidate rule methode, and region approach methode. From those three heuristic methode that used as solution of line balancing, there was improvement happenned with the same value in doors of production line. Line efficiency increased into 94,07% from 62,71% at the beginning condition. Balance delay increased into 5,92% from 37,28% at the beginning condition. The idle time descreased into 12,39 minutes from 116,87 minutes at the beginning condition. The smoothness index descreased into 7,44 from 64,67 at the beginning condition.


2012 ◽  
Vol 576 ◽  
pp. 700-704 ◽  
Author(s):  
Hartini Mustafa ◽  
Ahmad Razlan Yusoff ◽  
M. Yusoff Ismail

Assembly line balancing is assumed to have fixed task within specified task time during the initial stage of the mass production. The problem of current case study of this assembly line was the production line cannot meet the expected output plan with imbalance station cycle time. In this paper, productivity study and line balancing is applied to improve production line of GGMG & CALICO. The desired cycle time defined using the Standard Time Data (STD) which required the person to perform assign task till completion by defining the performance rating of person. The proposed solution proved by the implementation analysis conducted in the research. The results showed that the productivity of production line which is tremendously increased within 50% after implementation. There are six factors identified during the study which are bottleneck stations, workpiece flow, line layout, ergonomic, resource assignment and buffer allocation.


2012 ◽  
Vol 542-543 ◽  
pp. 320-323 ◽  
Author(s):  
Ling Zhao

The paper is focus on the assembly line of the factory .The nodular method and second-watch measuring methods are applied to measure the work time of the bottleneck stations. To improve the cycle time of the assembly line, the work contents of relative stations is reallocated. Finally, the production line is disposed again on the basis of the principle of ECRS and the line balancing theory .After implemented the new method, the capability of this production line has improved.


2014 ◽  
Vol 20 (5) ◽  
pp. 678-692 ◽  
Author(s):  
Pornthipa Ongkunaruk ◽  
Wimonrat Wongsatit

Purpose – The purpose of this paper is to improve the productivity of a large-sized frozen chicken manufacturer in Thailand. It analyses the production process based on work study principles and identifies the bottleneck operation. It develops three models for the chicken preparation process. Design/methodology/approach – First, analyse the current production system by collecting the cycle time of all operations in the production process based on work study principles. Then, design the production network and identify the bottleneck operation. After that, three methods – based on line balancing (LB), theory of constraints, and JIT concepts or ECRS (eliminate, combine, rearrange and simplify) – are proposed and implemented in the actual production line. Findings – With the ECRS concept, the authors implement combine by combining two stations into one station, such as handling and weighing, or weighing batter and mixing it with chicken. Then, Simplify is implemented at job E, or transporting chicken using a cart instead of walking. This method can improve the cycle time and reduce the number of employees. It can increase the line efficiency by up to 94.20 per cent, reduce the number of employees by 14 persons, and reduce the labour cost by 356,160 baht/year. Originality/value – Most agro-industry manufacturing processes are labour intensive. Thus, production LB can help increase productivity and reduce costs. The authors found that the case study company designed the production line without aligning it with the production network. A simple improvement can be made by adjusting the sequence of the work. In addition, the current production line was not lean. Implementation of the ECRS concept to improve production can reduce the waiting time and simplify the job.


2010 ◽  
Vol 3 (1) ◽  
pp. 66
Author(s):  
Teguh Baroto, Wahyu Eni Maryati

This rescarch aims to orange a balance production line 10 improve work efficiency to rice production output. This line balancing planning, we use Rank Position Weight ( RPW ). Using operation time data in every work station and also precedence diagram based on the shoes making process could be found elements/operation group involving a work station. With 3 cycles time such as 100,150 ang 160 seconds could be found a cycle time 150 seconds result minimum operation grouping of balance delay. From this planning could be concluded that there were 10 work stations with production output 168 part of shoes of day.


2014 ◽  
Vol 13 (02) ◽  
pp. 113-131 ◽  
Author(s):  
P. Sivasankaran ◽  
P. Shahabudeen

Balancing assembly line in a mass production system plays a vital role to improve the productivity of a manufacturing system. In this paper, a single model assembly line balancing problem (SMALBP) is considered. The objective of this problem is to group the tasks in the assembly network into a minimum number of workstations for a given cycle time such that the balancing efficiency is maximized. This problem comes under combinatorial category. So, it is essential to develop efficient heuristic to find the near optimal solution of the problem in less time. In this paper, an attempt has been made to design four different genetic algorithm (GA)-based heuristics, and analyze them to select the best amongst them. The analysis has been carried out using a complete factorial experiment with three factors, viz. problem size, cycle time, and algorithm, and the results are reported.


2014 ◽  
Vol 635-637 ◽  
pp. 1952-1955 ◽  
Author(s):  
Ji Jun Xiao ◽  
Shu Ou ◽  
Qing Hua Zhou ◽  
Hao Dong

Based on the principal concepts of streamline balance, this paper analyses the issue of the line balancing, through analyzing traditional assembly line balance method and having the bottleneck work processes to amend the parameters of the Workplace design, and then building up a multi-variety small-batch production line balancing mixed-model.


Author(s):  
José Itzcoatl Gomar-Madriz ◽  
Salvador Hernandez-González ◽  
Jaime Navarrete-Damián

The Hoist Scheduling Problem is combinatory, so tools such as mathematical programming need to be used to get the sequence of movements, respecting the constraints of the process by minimizing the cycle time. A sequence in which the order of movements follows the order of the process is known as the basic diagram. These schedules do not have any clearance for the hoist to make any other movements, resulting in a loss in productivity. This chapter takes the production line of a Mexican factory as a case study, analyzing the hoist's travelling speed to find sequences of movements that could improve productivity. The results of the study indicate that the cycle time has a nonlinear behavior in respect of the hoist's travelling speed and it was determined that there are travelling speeds for which sequences are obtained with enough clearance to make other movements and keep other carriers on the line. A suitable speed was estimated in the case.


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