Lean line balancing for an electronics assembly line. Assembly line design and balancing designing and balancing the audi b9 mirror assembly line at smr automotive mirrors technology, mosonszolnok, hungary master of science thesis in the masters programme production engineering ranjith raja department of product and production development division of production systems. Product flow is expected to fall within a pace that is less than or equal to the takt time. The solution procedures such as optimum seeking procedures, heuristic, simulation and other approaches have many ways in detail to solve the line balancing problem. The quality of production line would be shown on the productivity, line balancing index, and effectiveness on resources. What is line balancing and how to achieve it tulip. Line balancing techniques for manufacturing smf ccl. In a production line work is divided into individual tasks and assigned to consecutive workstations on the line. Keywords assembly line balancing, workstations, production and equipment cost. The production strategy is a key driver of the design of the core assets. Actually, many benefits for the studied electronics assembly line were brought, which could be considered as a force to apply lean line balancing tool. A strategy that concentrates on making quality products, in the.
After balancing, new manpower has been proposed and final capacity of each worker has been reallocated. Line of balance lob is a management control process for collecting, measuring and presenting facts relating to time see schedule control, cost and accomplishment all measured against a specific plan. In another word the company used line balancing for grow up the rate of production and decrease man power, idle time and buffer near machine, also used line balancing for produced more than 2 products. Introduction line balancing means the work element to be allocated equally in many work stations also to balance a line for better productivity. Apr 25, 2008 lecture series on project and production management by prof. Simulation for jewelry production process improvement using. Line balancing production and operations management in production, line balancing is useful tool. A set of tasks, each with a task time, precedence constraints among some of the tasks, a limited number of stations. By reducing idle time, line balancing ensures that there is minimum work in progress. Match the production rate after all wastes have been.
Production runs on a single line with 65 minutes of takt time with an exception in the preassembly line of two parallel lines of 19 stations and minutes of takt time. Introduction in order to obtain the maximum production, compan y must manage the production line very well. 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. Minimize the maximum amount of work assigned to any station, subject to. Optimize assembly production line using line balancing. This strategy involves setting a planned rate of production for necessary materials to be fabricated within a particular time frame. Introduction ine balancing means balancing the production line, or any assembly line.
Arranging stations in a sequence line for the product to move from one station to the next until its completion at the end of the line. Application of linebalancing to minimize the idle time of. General configuration of an automated production line keypoint in automated production unprocessed parts enter the production line and undergo a system of automated processing at various workstations along the fixed production line, with parts being moved from one workstation to the next by. Production runs on a single line with 65 minutes of takt time with an exception in the preassembly line of two parallel lines. The silencer assembly line is studied in this paper which assembles four products. Flexible line balancing uses the comsoal computer method of sequencing operations for an assembly line procedure to assign work elements to stations. Calculate theoretical minimum number of workstations. Therefore, from this case analysis, the production capacity is increased from 850 shirts per day to 1768 shirts per day and line efficiency of the line is improved from 69. The production plan for a product line captures the strategy for developing products from the core assets. Also, the assembly line needs to be designed effectively and tasks needs to be distributed among workers, machines and work stations ensuring that every line segments. In mass production on progressive assembly line the workload between various machines or workstations should be balanced. The results were considered satisfactory when assessed in terms of production capacity, manufacturing cycle time, and assembly line balancing. Lecture series on project and production management by prof. The used of line balancing technique was proved able to increase the productivity for the small medium enterprise.
The coreasset developers create the strategy while the core assets are being created. Mixed assembly line balancing method in scenarios with. Assembly line balancing to improve productivity using work sharing method in apparel industry. I am not at all familiar with line balance problems i dont know if any of us here will be, but it sounds like an old problem that people have been solving for a long time, and i expect some of them have been using spreadsheets for the solution. The production line balancing aims through effective activities and actions to ensure a continuous and level production, providing maximum productivity and efficiency while maintaining the proper work rhythm of the production process and avoiding wastage. This is necessary to avoid idle time or balancing loss since the work stations at each production stage for example drilling, milling, etc. Short but useless answer yes, i expect it is possible to do these things in excel just like in any other programming language. Transfer line balancing problem tlbp was introduced in in comparison with the wellknown assembly line balancing problems, tlbp has many new assumptions reflecting the particularities of the machining environment. Repeat for following workstations until all tasks are assigned. Abstract line balancing is an effective tool to improve the throughput of assembly line while reducing nonvalueadded activities, cycle time. Pdf line balancing using heuristic procedure and simulation. Optimizing assembly line production through line balancing. Line balancing, line balancing operations management. A system of managing production processes that result in linebalancing, onepiece flow, and little or no excess material inventory on hand.
An assembly line balancing is to know how tasks are to be assigned to workstations, so that the predetermined goal is achieved. You can run this pc software on windows xpvista7810 32bit. Flexible line balancing is an outstanding tool to raise productivity on any progressive assembly line. A production line is a set of sequential operations established in a factory where components are assembled to make a finished article or where materials are put through a refining process to produce an endproduct that is suitable for onward consumption.
We have compared the line graph after balancing the line, labor productivity and line efficiency. A system of managing production processes that result in line balancing, onepiece flow, and little or no excess material inventory on hand. Line balancing strategy is to make production lines flexible enough to absorb external and internal irregularities. Line balancing is the problem of assigning operation to workstation along an assembly line, in such a way that assignment is optimal in some sense. Production lines, product design, market demand, number of workers, technology or machines. Lean manufacturing application on balancing of mounting. Line balancing standardizes production, meaning it is much easier to avoid buildups or surplus inventory.
Assign tasks to first workstation, using rules and staying within cycle time. Pdf line balancing techniques for productivity improvement. Introduction production line the sequence of the machine and equipment arranged to produce the desired product various machine and equipment are designed to perform one or more operations required to produce item or product also the operating time of each machine will depend on the time required to complete the operation the out put produced by each machine during some. The takt time line balancing template package is a professionally produced, ready to use template that can be used in either a production or office environment. It shows the process, status, background, timing and phasing of the project activities, thus providing management with measuring tools that help. Keywords line balancing simulation software, production line, smv, time study, rpwm, precedence diagram 1. Balancing assembly lines is a very important mission for manufacturing industries in order to improve productivity by minimizing the cycle time or the number of. Line of balance lob 1 is a method of showing the repetitive. Several researchers proposed algorithms to look for optimal solutions of lb padron et al.
An example of line balancing simulation expert brian harrington discusses how simulation can play a key part in the successful completion of a manufacturing project when the conflicting objectives of cost, quality and time all need to be delivered on. The processes used to accomplish the assembly of the components can be divided into three major categories. Quickly and easily allocate any number of tasks to assembly line workstations with a software solution that provides the absolute minimum. Productionline balancing financial definition of production. Line balancing example omgt3123 tinas department needs to service 3,000 calls per 40hour workweek i. One of the main drawbacks for this type of production line is the difficulty of inprocess line balancing. The goal is to achieve the desired output rate with the smallest number of workstations. The issue of machine failure in an assembly line situation is tackled through simulation to showcase some interesting results that justify the inclusion of buffer stock.
Excel gantt chart tutorial how to make a gantt chart in microsoft excel 20 excel 2010 excel 2007 duration. The bus production system at man turkiye is divided into five operational lines that are chassis welding, paintshop, preassembly, assembly and finish. Flexible line balancing free version download for pc. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and no absorption of fixed costs. And finally, by bringing production time closer to takt time, it guarantees ontime delivery.
Assembly line balancing is a production strategy that sets an intended rate of production to produce a particular product within a particular time frame. Line of balance lob 1 is a method of showing the repetitive work that may exist in a project as a single line on a graph. The process of servicing calls can be broken down into the six stations listed above. Guidelines for developing a product line production plan. Machining transfer lines are usually paced and serial. Line balancing techniques to improve productivity using. In this case, a systematic technique or approach should be introduced. Wellbalanced lines avoid labour idealness and improve productivity. Arun kanda, department of mechanical engineering, iit delhi. Assembly line balancing to improve productivity using work.
Although the conveyor belt was first used by meat factories in chicago, ford made it known in 19. Assembly line balancing alb is the term commonly used to refer to the decision process of assigning tasks to workstations in a serial production system. Line balancing to minimize cycle time view the model download the model given. Line of balance 1 au this work is licensed under a creative commons attribution 3. It shows the process, status, background, timing and phasing of the project activities, thus providing management with measuring tools. Pdf the current issue of vikalpa carries a management case, production line balancing. Line balancing in production management mba knowledge base. Production actvity, assembly line, flexible layout, optimum. Line balancing is a major consideration in layout because a lack of balance can most easily hinder the production. The processes used to accomplish the assembly of the components can be divided into three major. Each task is assigned to exactly one station, no task is.
By using the lino balancing technique, the production will increase because the arrangement of the line is corrected and the maximum productivity will be archive. Minimization of the number of workstations and maximization of the production rate are the most common goals. 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. The need for balancing the line becomes obvious when it is considered that the output to be received from the. The intent of line balancing is to match the output rate to the production plan. Line balancing is the assignment of work elements to stations in a line. Any variance at any link in a theoretically balanced production chain will result in disruptions in production and could even stop the entire production line. For balancing it is not essential that output of each operation should be same but the essential is to see that output of fastest machine should be multiple of the output of the remaining other machines. Apr 07, 2014 excel gantt chart tutorial how to make a gantt chart in microsoft excel 20 excel 2010 excel 2007 duration.
Productivity improvement through line balancing in apparel. Introduction while looking at product layout there are many aspects to focus on. The literature calls such optimization as line balancing, and it is highly beneficial where mass production occurs and the products have been manufactured for a longer period of time in the same production line sivasankaran and shahabudeen 2014. Balance the line by assigning specific tasks to workstations. Line balancing is a manufacturingengineering function in which whole collection of production line tasks are divided into equal portions.
Production efficiency improvement by using tecnomatix. Line balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. Determining numbers of workstations and operators for a. Lecture 33 product layouts and assembly line balancing. Simulation for jewelry production process improvement. There is a logic therefore to setting the pace of production flow to this takt time. An efficient heuristic method for the simple assembly line balancing problem, international journal of production research, vol. Typically, raw materials such as metal ores or agricultural products such as foodstuffs or textile source plants like cotton and flax. Afterward time studies with respect to blouse production, which will be analysed in assembly line balancing, are conducted and information, which is necessary for assembly line balancing, is obtained. Apr 09, 20 in a production line work is divided into individual tasks and assigned to consecutive workstations on the line. The main objective of line balancing is to distribute the task evenly over the work station so that idle time of man of machine can be minimized.