Assembly Line Balancing: An effective tool for improving Productivity

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Introduction:

Because of increasing competition in apparel products in the global market, it is very important for apparel manufacturing industries to maintain the demand and deadline of shipments. In most of the assembly lines in the apparel industries, work-ers are not placed based on their skill which reduces produc-tivity and deteriorates deadline of shipments with increasing costs. This work is carried out for the purpose of analysis and development a frame work for improving productivity based on the performance of the workers. To develop the framework time study, fatigue study, worker performance has been stu-died.

What is assembly-line balancing?

  1. To a workstation within an assembly line in order to meet the required production rate and to achieve a minimum amount of idle time.
  2. Line balancing is the procedure in which tasks along Assigning each task the assembly line are assigned to work station so each has approximately same amount of work.

Unbalance Line and Its effect

  • High work load in some stages (Overburden)
  • Maximizes wastes (over-processing, inventory, waiting, rework, transportation, motion)
  • High variation in output
  • Restrict one piece flow
  • Maximizes Idle time
  • Poor efficiency

Balanced Line and its effect

  • Promotes one piece flow
  • Avoids excessive work load in some stages (overburden)
  • Minimizes wastes (over-processing, inventory, waiting, rework, transportation, motion)
  • Reduces variation
  • Increased Efficiency
  • Minimizes Idle time

How Can Assembly-Line Balancing   Help Organization ?

  • Increased efficiency
  • Increased productivity
  • Potential increase in profits and decrease in costs

Steps in Balancing an Assembly Line

  • List the sequential relationships among tasks and then draw a precedence diagram.
  • Calculate the required workstation cycle time.
  • Calculate the theoretical minimum number of workstations.
  • Choose a primary rule that will determine how tasks are to be assigned to workstations.
  • Beginning with the first workstation, assign each task, one at a time, until the sum of the task times is equal to the workstation cycle time or until no other tasks can be assigned due to sequence or time restrictions.
  • Repeat step 5 for the remaining workstations until all the tasks have been assigned to a workstation.
  • Evaluate the efficiency of the line balance.
  • Rebalance if necessary.

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