Line 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. ASSEMBLY
LINE BALANCING
PRESENTATION BY :-
AMAN SHYAMSUKHA
JECRC UNIVERSITY
Reg. No. -
1301021012

2. COMPANY PROFILE
Office / Factory Address: Eicher Engines -
A unit of TAFE Motors and Tractor
Ltd, Itarana Road, Alwar – 301001,
Rajasthan
Product: Automotive Engines
Stationary Engines
Agro / Industrial Engines
Year of Establishment: 1959

3. TMTL Engines Division is a unit of TAFE Motors and Tractors
Limited(TMTL) with Alwar, Rajasthan, India, as its manufacturing
base. TMTL is a wholly owned subsidiary of Tractors and Farm
Equipment Limited (TAFE), part of Chennai based
Amalgamations Group, which is one of India’s largest light
engineering conglomerates.
The TMTL Engines’ Alwar plant at Rajasthan, India, produces a
wide range of air and water cooled engines in the brand name
of EICHER ENGINES (upto 45 kVA) and TMTL ENGINES (62.5 kVA
and above), which carter to a wide range of automotive and
stationary applications and has an existing customer base of
over 700,000 spread across various segments

4. INTRODUCTION TO LINE
BALANCING
The main objective when it comes to the balancing of an assembly
line is the distribution of tasks among the stations to equalize the
workload between stations along the line.
Line 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.
Task allocation of each worker was achieved by assembly line
balancing to increase an assembly efficiency and productivity.

5. OBJECTIVE OF LINE BALANCING
Line balancing technique is used to:
To manage the workloads among assemblers.
To identify the location of bottleneck
To reduce production cost.
To improve productivity and efficiency of existing layout.
To decrease man power required in the assembly line.

6. ASSEMBLY LINES
Assembly lines include single-model assembly lines, mixed-model
assembly lines and multi model assembly lines. There are different
layouts of the different assembly lines and different assembly lines
may be operated differently.
Single model assembly line
Multi model assembly line
Mixed model assembly line

7. TERMS IN LINE BALANCING
Cycle time
Takt Time
Tolerance time
Takt overdue
Idle time
Productivity

8. ENGINES
Single cylinder assembly works for three types of engines used for different purposes.
AUTO ENGINE – For tractor use
ESG ENGINE – For genset use
NC ENGINE – For agriculture use.

9. METHODOLOGY
Introduction Current State Analysis Future State Mapping Verification and validation
of the system.
 Project initiation
 Problem definition
 Area of focus
 Observation at line
 Observation at
stations
 Evaluation of current
line balance
 Theoretical study
 Interview
 Data mining
 Time study
 Determination and
elimination of wastes
 Line balancing
 Operator planning
 Layout planning
 Theoretical study
 Interview
 Evaluation of proposed
system
 Recommendation for
future
 Project conclusion

10. AUTO ENGINE – ACTIVITY LIST
Processes Time
Put crank shaft in engine 43
Fit crank shaft in engine 92
Calibrate crank shaft & fill engine card 51
Fit crank gear 55
Fit idler and oil pump gear 48
Fit governor flange 12
Total Time (Seconds) 301

11. ESG ENGINE – ACTIVITY LIST
Processes Time
Put crank shaft in engine 43
Fit crank shaft in engine 92
Calibrate crank shaft & fill engine card 42
Fit crank gear 53
Fit PD gear 49
Fit oil ring & governor flange 30
Total Time (Seconds) 309

12. NC ENGINE – ACTIVITY LIST
Processes Time
Put crank shaft in engine 43
Fit crank shaft in engine 92
Calibrate crank shaft & fill engine card 42
Fit crank gear 55
Fit idler and oil pump gear 55
Fit governor flange 12
Total Time (Seconds) 299

13. YAMAZUMI CHART
The Yamazumi board provides a mechanism to quickly rebalance a
process when takt changes, and allows a visual indication of which
operations are overloaded (beyond takt), and which are underutilized.
Yamazumi charts for all three engines were plotted to check the
current state of the assembly line. In all the three graphs, there is a
black horizontal line showing the takt time is drawn. Processes having
cycle time above this line are undesirable and have a need to bring
under the tank time line.
Takt time > Cycle time

14. CURRENT YAMAZUMI CHART FOR AUTO ENGINE
288
406
359
301
245
147 152
314
199
242
306
260
438
197
182
236
315
275
436
216
163
338
0
50
100
150
200
250
300
350
400
450
500
TIME
STAGES
386

15. FUTURE YAMAZUMI CHART FOR AUTO ENGINE
288
350
359 357
245
0
308 314
199
242
306
260
375
260
0
236
315
341
355
216
345 338
0
50
100
150
200
250
300
350
400
SECONDS
STAGES
386

16. CURRENT YAMAZUMI CHART FOR ESG ENGINE
288
406
359
299
245
147 152
314
199
242
306
260
438
197 194
236
315
117
168 163
338
0
50
100
150
200
250
300
350
400
450
500
SECONDS
STAGES
386

17. FUTURE YAMAZUMI CHART FOR ESG ENGINE
288
350
359 355
245
0
308 314
199
294
306
260
375
260
0
236
315
0
233
357
338
0
50
100
150
200
250
300
350
400
SECONDS
STAGES
386

18. CURRENT YAMAZUMI CHART FOR NC ENGINE
326
418 413
309
278
147 155
314
250
357
254
285
443
186 182
320 315
298
234
163
332
0
50
100
150
200
250
300
350
400
450
500
SECONDS
STAGES
386

19. FUTURE YAMAZUMI CHART FOR NC ENGINE
326 323
373
349
278
0
311 314
250
357
254
285
380
249
0
334
315
298
234
345
332
0
50
100
150
200
250
300
350
400
SECONDS
STAGES
386

20. LINE EFFICIENCY
Line Efficiency = i=1
N
STi
m x C
x 100
Line efficiency of AUTO Engine is increased by 10.31%
Line efficiency of ESG Engine is increased by 9.95%
Line efficiency of NC Engine is increased by 9.75%

21. SMOOTHNESS INDEX
Smoothness Index = i=1
N
( 𝐶 − 𝑆𝑇𝑖)2
Smoothness index of AUTO Engine is improved by 53.08%
Smoothness index of ESG Engine is improved by 58.49%
Smoothness index of NC Engine is improved by 57.11%

22. MAN-POWER
AUTO ENGINE
There is requirement of 20 operators only as activities of ‘Spil Cut’ and
‘Control housing’ stage was transferred to other operators.
Productivity Increase = 10%
ESG ENGINE
There is requirement of 18 operators only as activities of ‘Spil Cut’ and
‘Control housing’ stage was transferred to other operators.
Productivity Increase = 14.29%
NC ENGINE
There is requirement of 19 operators only as activities of ‘Spil Cut’ and
‘Control housing’ stage was transferred to other operators.
Productivity Increase = 10.53%

23. CONTRIBUTION TO PROJECT
Studying the balancing and its related sequencing and scheduling
problems as an integrated problem
Have sole responsibility to accurately collect data from time study of
assembly line and proceed as well as to implement line balancing,
based on that data.
Increasing the line efficiency by providing unique intellects, such as:
moving the task of hammering dowel pin on L.O.P from assembly line
to washing to reduce operator fatigue and saving time.

24. LEARNING
The main objective is to look for the most efficient and economical
system. In method improvement only those operations are considered
which offer maximum potential for savings. New activities are
prepared for the selected operations, so as to examine them critically
and see how the assembly time could be reduced.

25. THANK YOU