Efficiency Improvement in the Assembly Line with the Application of Assembly Line Balancing Method

The focus of this paper is on the improvement of the assembly line by means of assembly line balancing approaches. The assembly line balancing is about evenly distribution of the work load among the workstations without violating the precedence and cycle time specifications. The twoassembly line balancing tactics specifically Largest candidate rule method (LCR) and Kilbridge and Westercolumn method (KWC) are utilized to strengthen the efficiency of assembly line by minimizing the number of workstations and thereby reducing the balance delay of the assembly line.Line balancing is an effective method to enhance the throughput of assembly line by reducing non-value-added activities. The technique followed includes calculation of cycle time of the process, identifying the non –value-added activities, calculating overall work load on station and distribution of work load on each station by the method of line balancing. This paper broadens the productivity and effectivity of an Excavator Assembly line in ABC organization. Line balancing is used to measure the efficiency of the line and later used to measure the effectiveness of the proposed solution. Multiple approaches have been proposed based on the time study carried out. Evaluation of the outcomes of the proposed assembly line suggests that the line efficiency of the excavator’s assembly line is improved from 71.27% to 77.44%

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A CASE STUDY ON IMPROVING THE PRODUCTIVITY USING IE TOOLS

International Journal of Mechanical and Industrial Engineering ◽

10.47893/ijmie.2013.1105 ◽

2013 ◽

pp. 249-252

Author(s):

BHAVIK SHAILESHKUMAR SHETH ◽

TANMAY SWAROOP ◽

RABINDER HENRY

Keyword(s):

Production Line ◽

Assembly Line ◽

Mixed Model ◽

Assembly Line Balancing ◽

Value Added ◽

Work Load ◽

Performance Measure ◽

Line Balancing ◽

Mixed Model Assembly Line ◽

Mixed Model Assembly

Assembly line balancing has been a focus of interest in Industrial Engineering for the last few years. Assembly line balancing is the problem of assigning tasks to workstations by optimizing a performance measure while satisfying precedence relations between tasks and cycle time restrictions. Line balancing is an important feature in ensuring that a production line is efficient and producing at its optimum. The process of Line balancing attempts to equalize the work load on each workstation of the production line. Mixed model assembly lines are increasing in many industries to achieve the higher production rate. This study deals with mixed-model assembly line balancing and uses Yamazumi chart to break down the work element in to the value added & Non-value added part to reduce the waste & increase the productivity.

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

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686714500085 ◽

2014 ◽

Vol 13 (02) ◽

pp. 113-131 ◽

Cited By ~ 2

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.

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Ergonomic risk and cycle time minimization for the U-shaped worker assignment assembly line balancing problem: A multi-objective approach

Computers & Operations Research ◽

10.1016/j.cor.2020.104905 ◽

2020 ◽

Vol 118 ◽

pp. 104905 ◽

Cited By ~ 8

Author(s):

Zikai Zhang ◽

QiuHua Tang ◽

Rubén Ruiz ◽

Liping Zhang

Keyword(s):

Cycle Time ◽

Assembly Line ◽

Assembly Line Balancing ◽

Line Balancing ◽

Worker Assignment ◽

Multi Objective ◽

Time Minimization ◽

Assembly Line Balancing Problem ◽

Ergonomic Risk

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Improving Assembly Line Efficiency and Output Using Assembly Line Balancing and Reducing Non-Value-Added Activities

Lecture Notes in Mechanical Engineering - Proceedings of the International Conference on Modern Research in Aerospace Engineering ◽

10.1007/978-981-10-5849-3_32 ◽

2018 ◽

pp. 333-339

Author(s):

Prateek Sharma ◽

Meeta Sharma

Keyword(s):

Assembly Line ◽

Assembly Line Balancing ◽

Value Added ◽

Line Balancing

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Assembly Line Balancing Type-2 Using Unequal Multiple Operators

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.816-817.1169 ◽

2013 ◽

Vol 816-817 ◽

pp. 1169-1173

Author(s):

Usman Attique ◽

Abdul Ghafoor ◽

Riaz Ahmed ◽

Shahid Ikramullah

Keyword(s):

Cycle Time ◽

Assembly Line ◽

Assembly Line Balancing ◽

Computational Effort ◽

Line Balancing ◽

Heuristic Methods ◽

Novel Approach ◽

Assembly Line Balancing Problem

Various exact and heuristic methods have been proposed for assembly line balancing problem (ALBP) but unequal multiple operators have not been considered much. In this paper we present a novel approach of assembly line balancing Type-2 with unequal multiple operators by using an already developed code in Matlab (Tomlab modeling platform). The adopted approach can be applied at line balancing problems ranging from few to hundreds of work elements to achieve minimum cycle time with very less computational effort.

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Effective Cycle Time: A Real World Balancing Index for Paced Assembly Lines

Journal of Advanced Computational Intelligence and Intelligent Informatics ◽

10.20965/jaciii.2010.p0431 ◽

2010 ◽

Vol 14 (5) ◽

pp. 431-441

Author(s):

Konstantinos N. Genikomsakis ◽

◽

Vassilios D. Tourassis

Keyword(s):

Performance Measures ◽

Cycle Time ◽

Assembly Line ◽

Assembly Line Balancing ◽

Line Balancing ◽

Research Trend ◽

Time Variability ◽

Assembly Lines ◽

Simulation Experiments

Assembly Line Balancing (ALB) aims at optimally assigning the work elements required to assemble a product to an ordered sequence of workstations, while satisfying precedence constraints. Notwithstanding the advances and developments in ALB over the years, recent and thorough surveys on this field reveal that only a small percentage of companies employ ALB procedures to configure their assembly lines. This paradox may be attributed, to some extent, to the fact that ALB is addressed mostly under ideal conditions. Despite the time variability inherent in manufacturing tasks, there is a strong research trend towards designing and implementing algorithms that consider ALB on a deterministic basis and focus on the optimality of the proposed task assignments according to existing ALB performance measures. In this paper, the need to assess the performance of the proposed solutions of various algorithms in the literature is corroborated through simulation experiments on a benchmark ALB problem under more realistic conditions. A novel ALB index, namely the Effective Cycle Time, ECT, is proposed to assess the quality of alternative assembly line configurations in paced assembly lines operating under task times variations.

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Productivity Study and Line Balancing of GGMG & CALICO Production Line

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.576.700 ◽

2012 ◽

Vol 576 ◽

pp. 700-704 ◽

Cited By ~ 1

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.

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