The document is a case study presentation on improving productivity through efficient line balancing at Runner Automobiles Ltd., focusing on a specific motorbike model. It outlines the methodology, objectives, problem definition, and techniques used in line balancing, notably comparing the rank positional and COMSOAL algorithm methods. The conclusion highlights that achieving higher line efficiency and balanced workloads among operators can significantly enhance production volume and profitability for the company.

1. Welcome to our
Presentation
Course No: IPE3600
Course Title: IPE Case Study

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

4. 1.
Topics of the case
study

5. “Study on improvement in Productivity
by developing an efficient Line Balancing
at Runner
Automobiles Ltd.

6. 1.
Introduction

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.

9. 2.
Objectives

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.

11. 3.
Problem Definition

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

13. 4.
Methodology

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

15. 5.
Methods of Line
Balancing

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.

18. 6.
Motor Bike
Elements

19. Basic elements of Motor Bike
Wheel
Hydraulic
plate of wheel
Saree guard
Muffler (Gas
exposer)Handle bar
Mad guard

20. Basic elements of Motor Bike
Shock absorberChassis (Frame) Gear lever
Chain Chain guard Head light

21. Basic elements of Motor Bike
Head Speedometer (Tachometer) Side cover
Fuel tank
Seat
Engine

22. 7.
Functions

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.

25. 8.
Line Layout

26. Line Layout
Pre Assembly
Section
Assembly
Section

27. Precedence diagram

28. 9.
Operation time
with predecessor

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

30. 10.
Calculation

31. Production time = 6 hour 30 minute = 23400 sec
Production volume = 100 unit/day for Royal+ bike
Cycle Time =
Production Time
Production Volume
=
23400
100
= 234 Second
SUACT = 44 + 19 + 41 + 54 + 38 + 12 +
14 + 4 + 22 + 24 + 84 +
94 + 4 + 12 + 108 + 5 + 116
= 695 Sec
Station Number = 17
Cycle Time = 234 Sec
∴ Balancing efficiency
= (1 -
𝑆𝑈𝐴𝐶𝑇
𝐶𝑇∗𝑆𝑁
) * 100%
= (1 -
591
234 ∗ 17
) * 100%
= 85%

32. 11.
Improvement

33. Proposed Model 1
On the basis of interchanging in assemble point

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

36. 11.
Overview of the
proposed model

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

38. 12.
Conclusion

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.

40. 13.
Reference

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