Line balancing techniques for manufacturing smf ccl. Abstract line balancing is an effective tool to improve the throughput of assembly line while reducing nonvalueadded activities, cycle time. Pdf line balancing techniques to improve productivity. Lean line balancing for an electronics assembly line. 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. First the backside seams and the combining two of those parts, by sewing the. Line balancing is great if you have a product that can sell all you produce that is, customer demand is infinite. 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. Assembly line balancing to improve productivity using work.
A novel assembly line balancing optimization algorithm based on psosa xiaomei hu1,a, yubin wang1,b, yangyang zhang1,c, xinran shi2,d 1the key laboratory of. Al hazza department of manufacturing and materials engineering international islamic university malaysia kuala lumpur 53100, malaysia r. In the assembly line, there are several stations that are composed of particular tasks. Assembly line balancing is common for flow oriented production systems. The core cause is the inefficiency of assembly line in the bus seat manufacturer. This is an efficient device to develop the throughput of assembly lines and work cells while decreasing manpower requirements and expenses. Manual singlestations assembly manual assembly line. Index terms about assembly line balancing, cycle time study, nonvalue. It shows the process, status, background, timing and phasing of the project activities, thus providing management with measuring tools that help. An example of line balancing adding operators to the analysis in this simulation we placed 3 operators to cover the 6 manual operations within the line. Pdf on aug 17, 2011, mohammad kamal uddin and others published. In this stage, standard time is calculated using work study.
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. In this case, a systematic technique or approach should be introduced. Line balancing for improving apparel production by. The solution procedures such as optimum seeking procedures, heuristic, simulation and other approaches have many ways in detail to solve the line balancing problem. Mixed assembly line balancing method in scenarios with. Line balancing in the real world emanuel falkenauer optimal design av. Pdf splitmerge is a standalone application that can be used to split, merge, and manage your pdf files, pdf split merge is offered as an easy to use gui graphical user interface application, and a command line application. This production line is for the assembly of a bicycle seen above. Production actvity, assembly line, flexible layout, optimum. Line balancing is the assignment of work elements to stations in a line. This paper outlines the key steps to take when starting out a line balancing. Al design model and solution methodology combine the model stage. Designing such a line is a very complex problem due to manufacturing. Lean forums line balancing to maximize labor utilization.
Remote access most decisionmakers conduct a significant portion of their business while out of the office. The used of line balancing technique was proved able to increase the productivity for the small medium enterprise. Line balancing also a successful tool to reduce bottleneck by balancing the task time of each work station so that there is no delays and nobody is overburden with their task. Pdf balancing the production line by the simulation and statistics. Assembly systems and line balancing discrete products are assembled from components.
Balancing mechanized or automated production lines with this method is more difficult since it is rarely possible to find equipment with identical cycle times. A production line is a very efficient way of manufacturing and assembling a product. Key advantage of using manual assembly line is specialization of labor by. The intent of line balancing is to match the output rate to the production plan. Line balancing techniques to improve productivity using. This research will attempt to overcome the problem by balancing its line and improved its efficiency. Assign tasks to first workstation, using rules and staying within cycle time. These standard models and the process of reduction are the topics of this chapter. Although there are many developed and solve assembly line balancing. Assembly line balancing to improve productivity using work sharing method in apparel industry. A novel assembly line balancing optimization algorithm. Guidelines for developing a product line production plan. In food processing plants, the production cycle time is based on worker pace, machine speed and conveyor speed. The concept of mass production essentially involves the line balancing in assembly of identical or interchangeable parts or components into the final product in various stages at different workstations.
Assembly line balancing alb and sequencing is an active area of optimization research in. Line balancing in production management mba knowledge base. Optimization of cycle time in an assembly line balancing problem. This strategy involves setting a planned rate of production for necessary materials to be fabricated within a particular time frame. The quality of production line would be shown on the productivity, line balancing index, and effectiveness on resources. Productivity improvement through line balancing in apparel industries md. 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. Assembly line balancing alb and sequencing is an active area of. Formulation of integer programming model for balancing and.
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. Job shop, batch production, mass production, manual. Pdf assembly line balancing and sequencing researchgate. Optimizing assembly line production through line balancing. Line balancing is a classic operations research optimization technique which has significant industrial importance in lean system. Repeat for following workstations until all tasks are assigned. Most businesses dont run at 100% efficiency so available working time normally has an efficiency ratio applied to it which will result in a shorter takt time meaning the production line needs to run slightly faster.
A case study article pdf available in applied mechanics and materials 4447 december 2010 with 3,756 reads how we measure reads. Pdf balancing and simulation of assembly line in an lcd. A production strategy that involves setting an intended rate of production for required materials to be fabricated within a particular time frame. Line balancing production and operations management in production, line balancing is useful tool. Linebalancing strategy is to make production lines stretchy enough to absorb external and internal indiscretion. The production strategy is a key driver of the design of the core assets. 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. Formulation of integer programming model for balancing and scheduling of production line having shared resources h. The original line balancing problem was developed to be cost efficient. Determine required workstations theoretical minimum 4.
Productivity improvement through line balancing in apparel. The first is the assignment of tasks to stations on the linethe line balancing. The goal is to achieve the desired output rate with the smallest number of workstations. Balancing and scheduling mixedmodel ushaped production. Actually, many benefits for the studied electronics assembly line were brought, which could be considered as a force to apply lean line balancing tool. Line balancing process is performed by plotting man machine charts to improve the. Line balancing and production line balancing process organization the line balancing is to design a smooth production flow by allotting processes to workers so as to allow each worker to complete the allotted workload within an even time line balancing process organization it is a system where you meet the production expectations and. Line balancing is about arranging a production line so that there is an even flow of production from one work station to the next. Line balancing is then conducted by reducing the number of workstation to three stations by combining the mould assembly and filling monomer into one station. Two important problems occur routinely with these lines. As the bicycle frame travels down the production line each person at a workstation workstation has a specific task to carry out see below. The coreasset developers create the strategy while the core assets are being created. The production plan for a product line captures the strategy for developing products from the core assets. This is necessary to avoid idle time or balancing loss since the work stations at each production stage for example drilling, milling, etc.
Timer pro software for assembly line balancing and lingo optimization software. Abstract in this paper, the post process operations of the housing manufacturing of common rail pump and line balancing and lean line design concepts are discussed. Line balancing, line balancing operations management. Line balancing lb is a classic, wellresearched operations research or optimization problem of. The results of the current situation and new cell design is summarized in table 3 are compared. Combining heuristic procedures and simulation models for balancing a pc camera. Therefore, the study will concentrate on manufacturers problem, which is efficiency of assembly line balancing for vip seats.
Modifying production line for productivity improvement. In addition, effective line balancing requires assuring that every line segments production quota can be met within the time frame using the available production capacity. The assembly line balancing is to assign the different tasks to various stations. The line of balance lob scheduling technique was originated by the goodyear company in the early 1940s and was developed by the u.
How to balance a manufacturing work cell quarterman lee. Optimize assembly production line using line balancing. Line balancing is an interesting ie topic and possibly off track for a lean forum. A set of tasks, each with a task time,precedence constraints among some of the tasks,a limited number of stations.
Efficiency improvement in the assembly line with the. Line balancing activities are usually undertaken to meet a specified output. Pros and cons of using lines merge in pdf files return to frequently asked questions. Does anyone know some assembly line balancing software. It is possible, however, to reduce any production systems to one of the small set of standard models.
Rezaul hasan shumon, kazi arifuzzaman and azizur rahman dept. Assembly process assembly involves the joining together of two or more. They consist to a set of workstations through which parts are manufactured. In the first scenario, the layout design of the factory has been improved with regard to production process and bottleneck station.
Additionally, successful line balancing requires assuring that every line segments production quota can be met within the time frame using the available production capacity. For the rest of the world we should build to takt, that. Line balancing for improving apparel production by operator skill matrix. Mathematical models for solving linear optimization problems through minimization or maximization of a linear function subject to linear constraints. Support for lines merge in pdf files is a huge feature in acroplot and it can save the user countless hours of messing with the draworder to get the proper results. The processes used to accomplish the assembly of the components can be divided into three major. If the work elements can be grouped so that all the station times are exactly equal, we have perfect balance. Can be used for all of single model mass production, multi model batch production and mixed model production systems. Tanjim hossain 1, mohammad abdul jalil 2, elias khalil 3. Line balancing and lean line design for common rail pump.