scholarly journals Time-Based Factory Efficiency Analysis | I.C. Engine Assembly Line

2021 ◽  
Author(s):  
Rauf Tailony ◽  
Ishaq Tailony
Keyword(s):  
Operations Research ◽  
Cycle Time ◽  
Production Line ◽  
Assembly Line ◽  
Cold Test ◽  
Efficiency Analysis ◽  
New Techniques ◽  
Leak Testing ◽  
Block Time ◽  
Overall Efficiency

Abstract Cold test stations are commonly arranged as sequential processes along a complete engine production line. The production line consists of several stations for engine building purposes, and before the engine exits the production line it passes through different validation and testing stations, such as leak testing stations, piston protrusion stations (known as torque to turn stations), and cold test stations. Each of these stations has a sequence of operation that is performed automatically or semi-automatic with the support of an operator. The waiting time until the engine finishes the operation in one station is called “cycle time”. The longer the cycle time the less efficient the production line. Cold testing stations are considered the most complicated and time-consuming, yet important test stations for engine and powertrain development. The lengthy cycle time affects the overall efficiency of the production line. This paper investigates the problem of the cycle time difference between consequent stations and its effect on the overall efficiency of the factory. New techniques and operations research methods are introduced aiming to recover from such a manufacturing obstacle. This research is investigating the limitations of a manufacturing operation standpoint. Each test station is treated as a block that simulates the actual station, and the overall factory workflow is described. Time-based equations governing block time, idling time, and utilization of the system are introduced, and the factory efficiencies are calculated and compared. After identifying the problem, a practical solution is explained.

Productivity Study and Line Balancing of GGMG & CALICO Production Line

2012 ◽  
Vol 576 ◽  
pp. 700-704 ◽  
Author(s):  
Hartini Mustafa ◽  
Ahmad Razlan Yusoff ◽  
M. Yusoff Ismail
Keyword(s):  
Cycle Time ◽  
Production Line ◽  
Assembly Line ◽  
Flow Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Buffer Allocation ◽  
Resource Assignment ◽  
Time Data ◽  
Current Case

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.

Based on Industrial Engineering Production System Analysis and Improvement Research

2012 ◽  
Vol 542-543 ◽  
pp. 320-323 ◽  
Author(s):  
Ling Zhao
Keyword(s):  
Cycle Time ◽  
Production System ◽  
Production Line ◽  
Assembly Line ◽  
System Analysis ◽  
New Method ◽  
Line Balancing ◽  
Work Time ◽  
Measuring Methods ◽  
Production System Analysis

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.

Detection of Nut Welding Using Poka-Yoke Roller Coaster Jig

2015 ◽  
Vol 761 ◽  
pp. 170-174 ◽  
Author(s):  
Wan Ahmad Najmuddin Wan Saidin ◽  
Azrul Zamir Mohd Idris ◽  
S. Ravi ◽  
Ahmad Mujahid Ahmad Zaidi ◽  
Nazrul Idzham Kasim
Keyword(s):  
Quality Control ◽  
Problem Solving ◽  
Quality Management ◽  
Cycle Time ◽  
Production Line ◽  
Assembly Line ◽  
Base Line ◽  
Roller Coaster ◽  
Research Outcomes ◽  
Management Concept

This paper describes the proposal of Poka Yoke Roller Coaster (PKYC) jig as a device to detect nut weld missing of door patch base line model (BLM) at assembly line station. The PKYC was proposed in order to detect nut weld missing problem and to reduce cycle time and manpower that lead to higher cost by applying quality management concept as a problem-solving tool. This special purpose tool was capable to meet specific job based on industrial need by providing repeatability, interchangeability and accuracy in the manufacturing of products. A Quality Control (QC) approachcalled the Zero Quality Control (ZQC) was used to achieve zero defects at production line. In order to reach zero defects, poka yoke method was applied in this research. Outcomes indicate that PKYC can be utilised as a custom-tailored jig for detecting nut weld missing as well as fulfilling other objectives.

Balancing and Optimization of Vacuum Cleaner Assembly Line

2011 ◽  
Vol 130-134 ◽  
pp. 3731-3735
Author(s):  
Yan Hua Ma ◽  
Fan Sen Kong ◽  
Ying Jiang ◽  
Yu Zhang ◽  
Yan Ao
Keyword(s):  
Operations Research ◽  
Production Line ◽  
Practical Problem ◽  
Assembly Line ◽  
Heuristic Method ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Vacuum Cleaner ◽  
Fundamental Notion

The article elaborates the fundamental notion theory of assembly line balancing, aiming at F company’s assembly line actuality. It solves the practical problem occurred on production line by using heuristic method, and finally uses the methods of allocation in operations research. After the manufactory line balancing analysis, it raises the assembly efficiency obviously. Heuristic method is simple and practical to master, and the method provided in this paper could be popularize to other similar manufacturing factory.

scholarly journals A Nonparametric Efficiency Analysis for a Sample of Kansas Swine Operations

1998 ◽  
Vol 30 (1) ◽  
pp. 189-199 ◽  
Author(s):  
William W. Rowland ◽  
Michael R. Langemeier ◽  
Bryan W. Schurle ◽  
Allen M. Featherstone
Keyword(s):  
Mathematical Programming ◽  
Efficiency Analysis ◽  
Firm Efficiency ◽  
Economic Competitiveness ◽  
Swine Operations ◽  
Programming Techniques ◽  
Overall Efficiency ◽  
Nonparametric Efficiency ◽  
Nonparametric Efficiency Analysis

AbstractThis study evaluates the economic competitiveness of a sample of Kansas farrow-to-finish operations by estimating relative firm efficiency using nonparametric mathematical programming techniques. Measures of technical, allocative, scale, economic, and overall efficiency are then related to farm characteristics to identify sources of efficiency. Results indicate that overall efficient farms produce a high quantity of pork per litter, produce a portion of their own feed grains, generate a large portion of their income from swine and other livestock enterprises, and have a lower debt-to-asset ratio.

Study and Analysis of GA-Based Heuristic Applied to Assembly Line Balancing Problem

2014 ◽  
Vol 13 (02) ◽  
pp. 113-131 ◽  
Author(s):  
P. Sivasankaran ◽  
P. Shahabudeen
Keyword(s):  
Cycle Time ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Optimal Solution ◽  
Vital Role ◽  
Line Balancing ◽  
Problem Size ◽  
Minimum Number ◽  
Assembly Line Balancing Problem ◽  
Balancing Efficiency

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.

scholarly journals PENYEIMBANGAN LINTASAN PRODUKSI DENGAN METODE HEURISTIK (STUDI KASUS PT XYZ MAKASSAr)

2016 ◽  
Vol 15 (2) ◽  
pp. 182
Author(s):  
SAIFUL .. ◽  
MULYADI HAMBALI ◽  
TRI MUHADI RAHMAN
Keyword(s):  
Cycle Time ◽  
Production Line ◽  
Idle Time ◽  
Line Balancing ◽  
Work Station ◽  
Line Balance ◽  
Smoothness Index ◽  
Positional Weight ◽  
Region Approach ◽  
Work Responsibility

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.

Hewlett-Packard Uses Operations Research to Improve the Design of a Printer Production Line

1998 ◽  
Vol 28 (1) ◽  
pp. 24-36 ◽  
Author(s):  
Mitchell Burman ◽  
Stanley B. Gershwin ◽  
Curtis Suyematsu
Keyword(s):  
Operations Research ◽  
Production Line ◽  
Hewlett Packard
Sign in / Sign up

Export Citation Format

Share Document