This presentation is on the based on case study done by using line balancing technique which a prime concern for an industrial engineer. This shows an efficient line balancing for a better production line performed at Runner Automobiles Ltd, Bangladesh.
BASIC POINTS RELATED TO SFC
The area in a manufacturing facility where assembly or production is carried out, either by an automated system or by workers or a combination of both. The shop floor may include equipment, inventory and storage areas.
OBJECTIVES,
Shop floor control is responsible for the detailed management of activities and the flow of materials inside the plant, including employees, materials, machines, and production time. ... Production and process order scheduling. Capacity requirements planning. Material availability assessment.
3 REALS
Go to the real place…
To observe the real thing…
To get the real facts and data.
4P MANAGEMENT
, SETUP, ACTIVITIES, SFCS, BENEFITS, 5S PROGRAM, GENERAL SAFETY RULES.
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.
Some days ago, I found a discussion about the difference between Efficiency and Productivity.
I tried to answer in that forum from my understanding. In that discussion i called OEE as Productivity.
BASIC POINTS RELATED TO SFC
The area in a manufacturing facility where assembly or production is carried out, either by an automated system or by workers or a combination of both. The shop floor may include equipment, inventory and storage areas.
OBJECTIVES,
Shop floor control is responsible for the detailed management of activities and the flow of materials inside the plant, including employees, materials, machines, and production time. ... Production and process order scheduling. Capacity requirements planning. Material availability assessment.
3 REALS
Go to the real place…
To observe the real thing…
To get the real facts and data.
4P MANAGEMENT
, SETUP, ACTIVITIES, SFCS, BENEFITS, 5S PROGRAM, GENERAL SAFETY RULES.
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.
Some days ago, I found a discussion about the difference between Efficiency and Productivity.
I tried to answer in that forum from my understanding. In that discussion i called OEE as Productivity.
AN EXPERIMENTAL STUDY ON THE AUTOMOTIVE PRODUCTION LINE USING ASSEMBLY LINE B...IAEME Publication
The main aim of an assembly line is to group the different facilities and workers inan efficient manner in order to obtain effective utilization of man power and machine.This calls for uniform rate of production as well as decrease in the work in process
inventory. Hence, this paper attempts to achieve these in an assembly line of anautomotive manufacturing unit using three different techniques such as Largestcandidate rule (LCR), Kilbridge and wester column method (KWC) and Rank
positional weighted method (RPW). All the three methods show better efficiency and acomparison is also drawn amongst the three to determine the best suited techniquepertaining to the current research work
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Optimization and Improvisation of Production Assembly Line of Two Valve Engin...IJERA Editor
In automobile engineering terminology a multi-valve engine is one where each cylinder has more than two valves. A multivalve engine has better breathing and can operate at higher revolutions per minute (rpm) than a two valve engine, delivering more power. Nowadays Eicher Motor is generating only two valve engines. But the need of the hour is to develop more efficient, four valve engines, which provide better fuel efficiency. Eicher Motor has started working on four valve engines because two valve engines apart from delivering inferior fuel efficiency compared to four valve engines also fall short on the front of emission norms compliance. To keep the transition two valve to four valve economical, it was proposed that instead of having an entirely new set up for assembling the four valve engines, two valve engine assembly line be use after required modification. For this change were made to engine assembly common line (Block), and cylinder head assembly line conveyors, location of cylinder head assembly line, manpower, machine and tools etc. of Eicher Motor as per the requirement of four valve and two valve assembly line and also engine assembly process was changed.
Poor layout design is determined as a major problem
in small and medium industry. These particular problems thus
affect the productivity and the line efficiency as well. In
automotive industries, assembly line is the major area to be
taken into consideration for increasing productivity. The focus
of this paper is to identify the bottleneck workstations in the
current layout and eliminate those activities that are taking time
on that workstations. The time study is done by using camera.
The current layout is redesigned by computing takt time and
processing times in each workstations. The case study shows how
the takt time calculation is done and from this takt time the
processing time is decided for all workstations. The time
consuming activities are reduced and thus the processing times
at all workstations is made possibly equal. The time reduction
increases productivity in the form of increased number of units
of production in the same previous time.
Line efficiency is also found to be improved which is described
with the terms Overall Line Efficiency (OLE) and First Pass
Yield (First Time Through) units.
Balancing the line by using heuristic method based on cpm in salbp –a case studyeSAT Journals
Abstract
In mass production systems, line balancing plays a great role, but this is not easy even if it is a simple straight line. So, in order to
solve these problems Heuristic methods are very much desirable. It is also found that Heuristic methods play a great role in the
formation of metaheuristic methods.Therefore it is very much important to use more efficient heuristic methods. In this research
paper we presents a heuristic method that is based on critical path method for simple assembly line balancing. This research is
mainly concerned with objectives of minimizing the number of workstations, improvement of smoothness index, mean absolute
deviation (MAD) and increasing line efficiency.
Keywords-Heuristic methods,Assembly line balancing problem, Critical path method, Simple assembly line balancing.
The use of mechanized and automated devices to perform the various assembly tasks in an assembly line or cell
Most automated assembly systems are designed to perform a fixed sequence of assembly steps on a specific product that is produced in very large quantities.
Modeling, simulation and optimization analysis of steering knuckle component ...eSAT Journals
Abstract Light weight and low fuel consumption are the two main demands for a vehicle, particularly for a race car. Steering knuckle, as one of the critical components of a race car, is the main subject in the present study. A light weight and optimized design of steering knuckle is proposed to be used for an EIMARace race car; a small high-performance formula-style car, with suitable material selection as well as valid finite element analysis and optimization studies. First part of this study involves modeling of steering knuckles and analysis of the stresses and displacement under actual load conditions. A CAD and FEA software; SolidWorks, is applied for modeling as well as for static analysis studies. Shape optimization is the second part of this study, utilizing solid Thinking software from Altair Engineering packages. The improved design obtained had achieved 45.8% reduction of mass while meeting the strength requirement. Keywords: Steering knuckle, FEA, Optimization, Race car.
Unit 8 - Information and Communication Technology (Paper I).pdfThiyagu K
This slides describes the basic concepts of ICT, basics of Email, Emerging Technology and Digital Initiatives in Education. This presentations aligns with the UGC Paper I syllabus.
How to Split Bills in the Odoo 17 POS ModuleCeline George
Bills have a main role in point of sale procedure. It will help to track sales, handling payments and giving receipts to customers. Bill splitting also has an important role in POS. For example, If some friends come together for dinner and if they want to divide the bill then it is possible by POS bill splitting. This slide will show how to split bills in odoo 17 POS.
How to Create Map Views in the Odoo 17 ERPCeline George
The map views are useful for providing a geographical representation of data. They allow users to visualize and analyze the data in a more intuitive manner.
2. Submitted By
Md. Abu Bakar Siddique
Roll: 125029
3rd Year, 6th Semester
Department of Industrial & Production Engineering
Rajshahi University of Engineering & Technology.
Submitted to
Sonia Akhter
Assistant Professor
Dept. of IPE
RUET, Bangladesh
3. Contents
Topics of our case study
Introduction
Objective
Problem Definition
Methodology
Methods of Line Balancing
Assembly Shop
Data
Calculations & Results
Improvement
Conclusion
7. Introduction
Increasing productivity has become a buzz word nowadays
on the basis of industry. There are several methods for
increasing productivity and Line Balancing is one of them.
Increase in production volume by decreasing cycle time is
the main task of line balancing.
There are 12 model motor bikes are manufactured by RAL
and we chose Royal+ bike due to its attractive look and its
high customer demand in the present market.
8. Literature Review
The Comsoal algorithm method of sequencing operation for assembly lines (Comsoal)
was developed by Arcus. The production generates a large number of feasible solution
using a simulation method.
The general algorithm of line balancing that we use for the further improvement was
done by Panneerselvam, et, aL, 1993. This algorithm is used both in Rank positional
method as well as in Comsoal algorithm method. The term idle time and down time are
not included in this algorithm method which creates an error some results.
Swapnil T. Firake and Dr. K. H. Inamdar wrote a journal on the topics of “Productivity
Improvement of Automotive Assembly Line through Line Balancing” where idle time,
down time and a non-value added activity is taken into consideration.
Muthanna Jamil and Noraini Mohd Razali wrote an journal on the topics of “Simulation
of Assembly Line Balancing in Automotive Component Manufacturing” where an
assembly line is developed on the basis of line balancing efficiency and minimum
percentages idle time.
10. Objectives
To study the current line balancing of Runner Automobiles Ltd.
Subdivide the network into several sub-networks.
Precedence relationship of that sub-networks are not violated.
Allocating operation to each station without exceeding the cycle
time.
Complete the assembly line with proper heuristics.
Finding out the limitations of existing line and then give a proper
solution.
12. Based on a preliminary study of the current production line
there exist three major problems.
Firstly, the production rate is not in optimum level on the basis
of cycle time. Secondly, the line is experiencing moderate line
efficiency. Thirdly, the job rotation is very acute there and so
the line is stopped uncertainly as the worker are not 100%
expert.
We work for improvement in productivity by solving this
situation applying the knowledge of line balancing.
Problem Definition
14. Results & Analysis
Verify the alternative line
Developing an advance alternative line
Analysis of present assembly line
Chose suitable algorithm
Data collection
Observation of assembly shop
Objective
Problem statement
16. • Rank Positional Method
• Comsoal Algorithm Method
Ways of finding
out Line
Balancing:
Rank Positional Method:
The ranked positional weight method was developed by Helgeson and Brinie. This
method assigned those jobs first whose follower have the largest total time. The
positional weight of a work element is its own processing time plus the processing
times of all the following work elements.
Comsoal Algorithm Method:
This computer method of sequencing operation for assembly lines was developed
by Arcus. The procedure generates a large number of feasible solutions using a
simulation method.
17. Why Comsoal Algorithm is better
than Rank positional method?
The two methods that mentioned are almost same in the sense of
general algorithm. But the difference is in their condition. The main
limitation of Rank Position Method is that the immediate
predecessor are already assigned to some station on the contrary
applying Comsoal Algorithm immediate predecessor are also
already assigned but not in some station. That could be assigned in
all stations or in no station. That’s the benefit of Comsoal Algorithm
Method and so we choose this method for the further calculations.
23. Operation Number Functions
Pre-assembly – 01 Unpacking & placing of all parts.
Pre-assembly – 02 Joining hydraulic plate to wheel.
Pre-assembly – 03 Blowing air to wheel.
Pre-assembly – 04 Joining rubber to the mat-guard.
Pre-assembly – 05 Joining light to the mat-guard.
Pre-assembly – 06 Joining parts of handle bar.
Pre-assembly – 07 Joining parts of speedometer.
Pre-assembly – 08 Joining light to head.
Pre-assembly – 09 Preparation of chassis.
Pre-assembly – 10 Assembling engine to chassis.
Assigned tasks
in pre assembly
24. Assigned tasks
in assembly
Operation Number Function
Assembly – 01 Assembling shock absorber & front wheel.
Assembly – 02 Assembling chain & chain guard.
Assembly – 03 Assembling back wheel.
Assembly – 04 Assembling mat-guard Screw tightening.
Assembly – 05 Assembling handle bar.
Assembly – 06 Assembling muffler.
Assembly – 07 Assembling gear lever.
Assembly – 08 Assembling speedometer.
Assembly – 09 Assembling electric wire.
Assembly – 10 Assembling Head & pumping point.
Assembly – 11 Assembling seat lock and saree guard.
Assembly – 12 Assembling fuel tank cover.
Assembly – 13 Assembling side cover and seat.
29. Operation No
Duration
(Sec)
Immediate predecessor
PA 1 190 --
PA 2 55 PA 1
PA 3 32 PA 1, PA 2
PA 4 145 PA 1
PA 5 150 PA 1, PA 4
PA 6 137 PA 1
PA 7 90 PA 1
PA 8 100 PA 1
PA 9 180 PA 1
PA 10 196 PA 1, PA 9
A 1 210 PA 1, PA 2, PA 3
A 2 60 PA 1
A 3 120 PA 1, PA 2, PA 3
A 4 118 PA 1, PA 4, PA 5
A 5 140 PA 1, PA 6
A 6 215 PA 1
A 7 160 PA 1
A 8 180 PA 1, PA 7
A 9 193 PA 1
A 10 222 PA 1, PA 8
A 11 167 PA 1
A 12 130 PA 1
A 13 109 PA 1
PA = Pre Assembly
A = Assembly
34. 0
100
2 7
13 13
7
30
21
0
150
2 0 0
55 55
37
21
0
20
40
60
80
100
120
140
160
Assembly
line
A2 A4 A9 A8 A11 A7 A12 A13
Time
Assembly points
Idle time vs Assembly line
Graphical representation
Idle time of present assembly line
Idle time of proposed assembly line
Figure: Difference of idle between present and proposed Assembly line.
35. There is a chance of reduction of work station. Work station 17 is used for only Assembly point
A4 (Assembling mat-guard Screw tightening). It takes in average 118 sec. if we could reduce it
to 108 sec by involving an extra worker
Assembly point Operation duration
(Sec)
Corresponding sub-assembly
A4 118 PA1, PA4, PA5
This A4 assembly can be done in workstation 15 instead of workstation 17, if A4 = 108 seconds.
If A4 = 108, then it can be carried in workstation 15, because workstation 15 has 108 SUACT.
So let, A4 = 108 then
Balancing efficiency = (1 -
𝑆𝑈𝐴𝐶𝑇
𝐶𝑇∗𝑆𝑁
) * 100%
= (1 -
591−108
234 ∗ 16
) * 100%
= 87%
Proposed Model 2
37. Items Details Efficiency Maximum Idle time
Proposed model 1
Three unites of workstation
added
In A1 assembly point,
assembly line is redesigned.
94% 6%
Proposed model 2
Faster production in A4
assembly point.
87% 13%
Overview on proposed models
39. Conclusion
The goal of the line balancing is to make an efficient line to
improve production volume from the existing production
line. The assembly line needs to balance so that the line
has the high value of efficiency. Higher value of line
efficiency indicates that the line have the approximately
equal cycle time between operators along the line. Besides
that, the workload between operators also distributed
equally which make the higher line efficiency. As Runner
Automobiles Ltd is in premature age so the line balancing
can bring a great help to increase the profit of the company.
Finally the case study is successfully completed with the
help of our honourable adviser Assistant Professor Sonia
Akhter and we are really thankful to her.
41. References
Pannerselvam, R. 2013, Production and Operation
Management, 3rd ed, PHI Learning Private Limited, Delhi –
110092, 219 – 240.
Firake, S.T & Dr. Inamdar, K.H, 2014, Productivity
Improvement of Automotive Assembly Line Through Line
Balancing, Volume 2, Issue 3 (May-June 2014), PP. 124-
128
Jamil, M. & Rajali, N.M., 2015, Simulation of Assembly
Line Balancing in Automotive Component Manufacturing
42. Thanks to all…
For contact: http://bit.ly/2fy1aiz
Email: mabs.ipe12@yahoo.com