The used of line balancing technique was proved able to increase the productivity for the small medium enterprise. Flexible line balancing free version download for pc. Assembly lines are cost efficient production systems that mass produce identical products. Assign tasks to first workstation, using rules and staying within cycle time. A strategy that concentrates on making quality products, in the. 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.
Conventional methods and extensions alexandre dolgui and jeanmarie proth ecole nationale superieure des mines, umr cnrs 6158 limos 158 cours fauriel, 42023 saintetienne cedex 2, france email. This strategy involves setting a planned rate of production for necessary materials to be fabricated within a particular time frame. Optimize assembly production line using line balancing. Introduction in order to obtain the maximum production, compan y must manage the production line very well. Linebalancing strategy is to make production lines stretchy enough to absorb external and internal indiscretion. The silencer assembly line is studied in this paper which assembles four products. Lini produksi production line adalah urutan stasiun kerja dimana setiap stasiun kerja dirancang untuk mengerjakan tahap khusus dari proses produksi efisiensi akan meningkat ketika pekerja secara khusus diberi tanggung jawab pada suatu pekerjaan, sehingga pekerja dapat menggunakan keahliannya dengan tepat. To stay efficient, management decisions for the line such as number of workers and assembly task assignment to stations need to be optimized to increase throughput and decrease cost. In mass production on progressive assembly line the workload between various machines or workstations should be balanced. Before the advent of the assembly line, when a commercial good was manufactured, it was usually created by hand, from individually fabricated parts. A system of managing production processes that result in line balancing, onepiece flow, and little or no excess material inventory on hand. Line balancing means balancing the line, for example balancing the production line or an assembly line.
Scheduling optimization with line of balance and start. In this way you can easily map both current and future state conditions. Line and work cell balancing is an effective tool to improve the throughput of assembly lines and work cells while reducing manpower requirements and costs. The quality of production line would be shown on the productivity, line balancing index, and effectiveness on resources.
And finally, by bringing production time closer to takt time, it guarantees ontime delivery. Download32 is source for flexible line balancing shareware, freeware download elcomsoft distributed password recovery, model c1a3f297 command line translator 1. Jan 03, 2014 good line balancing increase the rate of production. Implementing line balancing methods with simulation simul8. Apr 09, 20 production lines are particularly appropriate for high volume operations. Every chart view and report wtihin line balancing then provides an aggregated and detailed analysis of the varying labor time that each product. Based on data collected through observations, interviews and study of production documents and reports, line balancing has been identified as a problem that is affecting the efficiency of the production line. Line balancing techniques to improve productivity using. Production lines are particularly appropriate for high volume operations. Profit of a factory can be ensured by proper line balancing. Welcome to production line balancing plb production line balancing ensures that there is no build up in the inventory in a line.
A system of managing production processes that result in linebalancing, onepiece flow, and little or no excess material inventory on hand. The processes used to accomplish the assembly of the components can be divided into three major. Lime balancing aims at grouping the facilities or workers in an efficient pattern in order to obtain an optimum or most efficient balance of the capacities and flows of the production or assembly processes 1. Line balancing techniques for manufacturing smf ccl. With so many different requirements on the system, the outcomes of process improvement changes can difficult to predict. Suppose there are three machines work stations a, b and c, which can process 5, 10 and 15 pieces per unit time respectively and the. 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.
It also helps to identify bottlenecks in operation and ways of balancing the activity. 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. Line balancing standardizes production, meaning it is much easier to avoid buildups or surplus inventory. 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. This paper outlines the key steps to take when starting out a line balancing. 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. Lecture 33 product layouts and assembly line balancing. What is line balancing and how to achieve it tulip. Productionline balancing financial definition of production. Such a concept is similar to the concept of takttime from the toyota production system ohno, 1988. In a production line work is divided into individual tasks and assigned to consecutive workstations on the line. The current project addresses the productivity improvement of a manual assembly line by making use of operations analysis in the framework of lean production. Balancing and sequencing of mixed model assembly lines by. Many of these deviations are internal to the assembly line balancing problem itself, arising from any.
Line balancing helps to compare the required machinery with the existing one and compare balance. Landasan teori line balancing menurut gaspersz 2004, line balancing merupakan penyeimbangan penugasan elemenelemen tugas dari suatu assembly line ke work stations untuk meminimumkan banyaknya work station dan meminimumkan total harga idle time pada semua stasiun untuk tingkat output tertentu. Line balancing part 5 balancing using paper february 23, 2016 lean tools information flow, lean tools, material flow, shopfloor christoph roser the previous four posts in this series for line balancing all looked at how to prepare the data and do some initial calculations. Line balancing production and operations management in production, line balancing is useful tool. Arun kanda, department of mechanical engineering, iit delhi. Assembly line balancing to improve productivity using work. The methodology consists of selecting a product or product family. By reducing idle time, line balancing ensures that there is minimum work in progress. Assembly line design and balancing pdf book manual free. Reduction of manufacturing cycle time using line balancing. 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 assembly lines are the most important components of mass production systems.
An assembly line balancing is to know how tasks are to be assigned to workstations, so that the predetermined goal is achieved. This is necessary to avoid idle time or balancing loss since the work stations at each production stage for example drilling, milling, etc. A methodology is proposed that helps to improve the productivity of any production process. Video made to show how, without the balancing, there will always be machine and worker waitings, with a following productive loss. After balancing, new manpower has been proposed and final capacity of each worker has been reallocated. This study aims to improve the productivity and efficiency of the production line in a small and medium size food industry. The processes used to accomplish the assembly of the components can be divided into three major categories. 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 goal is to achieve the desired output rate with the smallest number of workstations.
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. It is said to be a static imbalance when people, machines, or even workstations are underutilized. Determine required workstations theoretical minimum 4. The solution procedures such as optimum seeking procedures, heuristic, simulation and other approaches have many ways in detail to solve the line balancing problem. Line balancing is a manufacturingengineering function in which whole collection of productionline tasks are divided into equal portions. 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. Wellbalanced lines avoid labour idealness and improve productivity. Apr 25, 2008 lecture series on project and production management by prof. Line balancing in production management mba knowledge base.
Many of these deviations are internal to the assembly line balancing problem. Productivity improvement through line balancing in apparel. Keywords assembly line balancing, workstations, production and equipment cost. Justintime systems, lean manufacturing, and agile manufacturing 1 week 11. Textile and apparel industries are time consuming and labor oriented. Suppose there are three machines work stations a, b and c, which can process 5, 10 and 15 pieces per unit time respectively and the pieces flow from a to b to c precedence constraint.
Pdf line balancing techniques for productivity improvement. Production actvity, assembly line, flexible layout, optimum. 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. An assembly line is suitable for a type of industrial production in which prefabricated. Introduction ine balancing means balancing the production line, or any assembly line. Assembly systems and line balancing discrete products are assembled from components. Line balancing can be a challenge for manufacturers. Pdf the current issue of vikalpa carries a management case, production line balancing. It shows the process, status, background, timing and phasing of the project activities, thus providing management with measuring tools that help. Good line balancing increase the rate of production. The borders of the assembly line balancing problem, as classically drawn, are as clear as any other operations research topic in production planning, with welldefined sets of assumptions, parameters, and objective functions. Introduction while looking at product layout there are many aspects to focus on. 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. The line balancing module leverages assembly planners process planning structure that makes it easy to identify common tasks as well as tasks that are unique to one or more product model or option.
Line balancing is a major consideration in layout because a lack of balance can most easily hinder the production. It also helps in the determination of labor requirement. Repeat for following workstations until all tasks are assigned. To balance a production line comparing the productivity and efficiency before and after implementing the balancing technique in line. A single click will pass the current balance results into a value stream map template. Todays highly competitive market influences the manufacturing industry to improve their production systems to. Flexible line balancing is an outstanding tool to raise productivity on any progressive assembly line. Abstract line balancing is an effective tool to improve the throughput of assembly line while reducing nonvalueadded activities, cycle time. Lean line balancing for an electronics assembly line. Download assembly line design and balancing book pdf free download link or read online here in pdf. 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. 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. Line balancing, line balancing operations management.
Minimization of the number of workstations and maximization of the production rate are the most common goals. Learning factories based on realistic physical infrastructure provide engineering students with actionoriented learning conditions that. Line balancing is the assignment of work elements to stations in a line. Line balancing is about arranging a production line so that there is an even flow of production from one work station to the next. When you are talking about production line balancing, it is important to notice that there are 2 different types of line balancing.
Line balancing methods heuristic and stochastic 1 week. The static balance refers to the longterm differences in capacity during a period that shouldnt be inferior to several hours. Production lines, product design, market demand, number of workers, technology or machines. Master production planning and materials requirements planning mrp 2 weeks 12. All books are in clear copy here, and all files are secure so dont worry about it.
It shows the process, status, background, timing and phasing of the project activities, thus providing management with measuring tools. Flexible line balancing uses the comsoal computer method of sequencing operations for an assembly line procedure to assign work elements to stations. Linebalancing strategy is to make production lines flexible enough to absorb external and internal irregularities. In this case, a systematic technique or approach should be introduced. Therefore to control cost and waste reduction is main concerns for maintaining the economy of these industries. They analysed the time study of the precooking process at a frozen chicken company and proposed to improve the productivity by integrating ecrs and line balancing concepts. You can run this pc software on windows xpvista7810 32bit. A number of techniques are followed to control the overall cost like. Actually, many benefits for the studied electronics assembly line were brought, which could be considered as a force to apply lean line balancing tool for other production lines. Due to customer demand, manufacturers use mixed model assembly lines to produce customized products that are not identical. To obtain the just in time, it is necessary to establish a system. In application, however, these borders are frequently transgressed. It is easier to balance an assembly line operation than a.