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.

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 Two-Sided assembly line balancing to minimize number of workstation with considering the relationships between tasks

2018 ◽  
Vol 204 ◽  
pp. 02015
Author(s):  
Dina Rachmawaty ◽  
Putu Dana Karningsih ◽  
Budi Santosa
Keyword(s):  
Conceptual Model ◽  
Production Line ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Production Plan ◽  
Two Factors ◽  
Improvement Method ◽  
Increase Productivity ◽  
Assembly Line Balancing Problem

There are many problems in assembly line. Some of the problems are assembly line reliability which relates to maintenance and unbalance workload. As a result, production line is not efficient and production plan is not fulfilled. Previous research on two-sided assembly line balancing problem has proprosed improvement method by considering index relationship between tasks. There are only two factors that is taken into account in this research, they are: distance factor of the implementation of the task (distance factor) and tools used to perform the task (tool factor). Therefore, this paper aims to develops conceptual model by considering additional factors that affecting Assembly Line Tasks Consistency (ATC). The additional factors that are considered are as follow: distance factor, tool factor, motion factor, layout factor, and skill factor. The purpose of this conceptual model is to increase productivity by minimizing number of workstations. Linear combination are used to find a combination solution of a relationship between task to complete a two-sided assembly line balancing problem. Improvement of proposed assembly line are measured according to Balance Delay (BD) and Line Efficiency (LE).

Assembly Line Balancing Type-2 Using Unequal Multiple Operators

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.

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

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.

scholarly journals A CASE STUDY ON IMPROVING THE PRODUCTIVITY USING IE TOOLS

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.

scholarly journals Cycle time enhancement by simulated annealing for a practical assembly line balancing problem

Informatica ◽  
2020 ◽  
Vol 44 (2) ◽  
Author(s):  
Huong Mai Dinh ◽  
Dung Viet Nguyen ◽  
Long Van Truong ◽  
Thuan Phan Do ◽  
Thao Thanh Phan ◽  
...  
Keyword(s):  
Simulated Annealing ◽  
Cycle Time ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Assembly Line Balancing Problem

Reconfiguration of assembly line balancing–an automobile case study solved by the exact solution procedure

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ashish Yadav ◽  
Shashank Kumar ◽  
Sunil Agrawal
Keyword(s):  
Cycle Time ◽  
Assembly Line ◽  
Real Life ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Mixed Integer ◽  
Second Step ◽  
Automobile Plant ◽  
Content Type

PurposeMulti-manned assembly lines are designed to produce large-sized products, such as automobiles. In this paper, a multi-manned assembly line balancing problem (MALBP) is addressed in which a group of workers simultaneously performs different tasks on a workstation. The key idea in this work is to improve the workstation efficiency and worker efficiency of an automobile plant by minimizing the number of workstations, the number of workers, and the cycle time of the MALBP.Design/methodology/approachA mixed-integer programming formulation for the problem is proposed. The proposed model is solved with benchmark test problems mentioned in research papers. The automobile case study problem is solved in three steps. In the first step, the authors find the task time of all major tasks. The problem is solved in the second step with the objective of minimizing the cycle time for the sub-tasks and major tasks, respectively. In the third step, the output results obtained from the second step are used to minimize the number of workstations using Lingo 16 solver.FindingsThe experimental results of the automobile case study show that there is a large improvement in workstation efficiency and worker efficiency of the plant in terms of reduction in the number of workstations and workers; the number of workstations reduced by 24% with a cycle time of 240 s. The reduced number of workstations led to a reduction in the number of workers (32% reduction) working on that assembly line.Practical implicationsFor assembly line practitioners, the results of the study can be beneficial where the manufacturer is required to increased workstation efficiency and worker efficiency and reduce resource requirement and save space for assembling the products.Originality/valueThis paper is the first to apply a multi-manned assembly line balancing approach in real life problem by considering the case study of an automobile plant.

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