Productivity Improvement of an Assembly Line Through Line Balancing and Yamazumi: A Case Study Of Cummins Turbo Technologies, Dewas

2021 ◽  
Vol 6 (1) ◽  
pp. 21-29
Author(s):  
Adarsh Atre ◽  
Milind Dandekar
Keyword(s):  
Assembly Line ◽  
Line Balancing ◽  
Productivity Improvement

A Productivity Improvement of a Packing Line

2015 ◽  
Vol 789-790 ◽  
pp. 1240-1244
Author(s):  
Peeyapach Jitchaiyaphum ◽  
Suksan Prombanpong
Keyword(s):  
Production Line ◽  
Assembly Line ◽  
Waste Reduction ◽  
Line Balancing ◽  
Assembly Lines ◽  
Customer Demand ◽  
Productivity Improvement ◽  
Manual Assembly ◽  
Line Design

The purpose of this paper is to demonstrate a productivity improvement through waste reduction and line balancing. One of the obstacles of a manual assembly line nowadays is an awkward line design with over manpower, a lot of wastes, and low balance efficiency. As a result, the production line may not satisfy customer demand and ends up with low production line efficiency. This is due to the fact that this type of production line is operated by human and the customer demand or requirements are frequently fluctuated. Human workers are prone to make mistakes, inefficient, and unorganized. Thus, the major causes of production line down time are discussed with suggestion of remedy actions to improve the productivity. In addition, calculation of line balancing is demonstrated. One of the actual manual assembly lines will be used as a case study. It is found that after improvement line balance efficiency is increased from 46.49 to 86.66 percent with the productivity improvement of 159 percent.

A Productivity Improvement of a Cookware Assembly Line

2015 ◽  
Vol 799-800 ◽  
pp. 1398-1402 ◽  
Author(s):  
Jongrak Niamsawan ◽  
Suksan Prombanpong
Keyword(s):  
Cycle Time ◽  
Assembly Line ◽  
Line Balancing ◽  
Productivity Improvement ◽  
Motion Study ◽  
Machine Layout ◽  
Workplace Organization ◽  
Bottle Neck ◽  
Assembly Operations ◽  
Working Method

This research objective is to improve the productivity of cookware assembly line by means of time and distance reductions. The motion study and line balancing techniques were applied to the entire assembly operations. A bottle neck was identified to where the operation with inadequate machine layout and workplace organization, including the unbalanced workloads. The new workplace layout and new working method for operators were designed and implemented as well as balancing the assembly line. Specifically, the conveyor speed and duration between the consecutive workpieces in the production line were adjusted to 0.10 m/s and 50 cm, respectively. The number of operators needed in the process can be reduced from 14 persons to 11 persons. The cycle time for assembling process is decreased from 12 to 5 second.

Improved moth flame optimization algorithm to optimize cost-oriented two-sided assembly line balancing

2019 ◽  
Vol 37 (2) ◽  
pp. 638-663
Author(s):  
Mohd Fadzil Faisae Ab. Rashid ◽  
Ahmad Nasser Mohd Rose ◽  
Nik Mohd Zuki Nik Mohamed ◽  
Fadhlur Rahman Mohd Romlay
Keyword(s):  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Benchmark Problems ◽  
Labor Costs ◽  
Power Cost ◽  
Content Type ◽  
Set Up ◽  
Line Design

Purpose This paper aims to propose an improved Moth Flame Optimization (I-MFO) algorithm to optimize the cost-oriented two-sided assembly line balancing (2S-ALB). Prior to the decision to assemble a new product, the manufacturer will carefully study and optimize the related cost to set up and run the assembly line. For the first time in ALB, the power cost is modeled together with the equipment, set up and labor costs. Design/methodology/approach I-MFO was proposed by introducing a global reference flame mechanism to guide the global search direction. A set of benchmark problems was used to test the I-MFO performance. Apart from the benchmark problems, a case study from a body shop assembly was also presented. Findings The computational experiment indicated that the I-MFO obtained promising results compared to comparison algorithms, which included the particle swarm optimization, Cuckoo Search and ant colony optimization. Meanwhile, the results from the case study showed that the proposed cost-oriented 2S-ALB model was able to assist the manufacturer in making better decisions for different planning periods. Originality/value The main contribution of this work is the global reference flame mechanism for MFO algorithm. Furthermore, this research introduced a new cost-oriented model that considered power consumption in the assembly line design.

Efficiency Enhancement in a Medium Scale Gearbox Manufacturing Company through Different Lean Tools - A Case Study

2018 ◽  
Vol 34 ◽  
pp. 128-138 ◽  
Author(s):  
V. Saravanan ◽  
S. Nallusamy ◽  
Abraham George
Keyword(s):  
Lean Manufacturing ◽  
Processing Time ◽  
Assembly Line ◽  
Value Added ◽  
Value Stream Mapping ◽  
Productivity Improvement ◽  
Medium Scale ◽  
Value Stream ◽  
Manufacturing Company

Productivity is an important parameter for all small and medium scale manufacturing industries. Lean manufacturing emerged as production strategy capable of increasing productivity by identifying and eliminating non value added activities. This article deals with productivity improvement in a pre-assembly line of gearbox manufacturing company with a case study using lean concepts like process flow chart, process Gantt chart and time study. This paper illustrates using a case study on how a value stream mapping has to be carried out in a planet carrier pre-assembly line. Value stream mapping and work standardization are the key tools used in lean manufacturing and lean transformation. It makes the process smoother, helps in reduction of lead time and ultimately increasing the productivity. From the observed results it was found that, the productivity has been increased from 7 pieces to 10 pieces in the first step assembly when the proposed VSM was implemented. The second step processing time was reduced by the execution of proposed value stream mapping with TAKT time of 126 minutes and 165 minutes of processing time for demand of 10 pieces were achieved and the overall processing time has been reduced by about 24%.

2313 Regaining Productivity Through Line Balancing : A Case Study in an Electrical Manual Assembly Line

2014 ◽  
Vol 2014.24 (0) ◽  
pp. _2313-1_-_2313-6_
Author(s):  
Adi SAPTARI ◽  
Jia Xin LEAU ◽  
Nor Akramin MOHAMAD ◽  
Effendi MOHAMAD
Keyword(s):  
Assembly Line ◽  
Line Balancing ◽  
Manual Assembly

Optimizing Assembly Line Production through Line Balancing: A Case Study

2015 ◽  
Vol 761 ◽  
pp. 104-108
Author(s):  
Adi Saptari ◽  
Jia Xin Leau ◽  
M. Nor Akramin
Keyword(s):  
Cycle Time ◽  
Assembly Line ◽  
Line Balancing ◽  
Additional Increase ◽  
Line Production ◽  
System A ◽  
Line Setting ◽  
Assembly Operations ◽  
Current Systems

In Line Balancing principles, the total workload in the assembly process is divided as evenly as possible among the workstations, without violating the sequences and relations in the assembly operations. Line balancing is important in an assembly system as it balances the line and increases the efficiency, as well as the productivity of a system. A case study was conducted in the assembly line of an electrical accessories manufacturer in Malaysia. The cycle time for each station was recorded, and the standard cycle time was estimated. The productivity, as well as the efficiency of the current assembly line, were studied. In terms of the productivity, the performance of the current systems was 500 units/worker/day, while the expected productivity was 600 units/worker/day. An assembly line setting was proposed based on the Line Balancing Method; the productivity for the proposed line increased to 671 units/worker/day, or in rough additional increase around 34%.

Assembly line balancing by computer: a case study

1974 ◽  
Vol 53 (9) ◽  
pp. 321 ◽  
Author(s):  
Geoff Buxey ◽  
Martin Burke
Keyword(s):  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing

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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