Analysis and balancing of assembly line in a machine molding factory

Year 2021, Volume: 5 Issue: 1, 87 - 96, 15.04.2021

Esra Can Adalet Öner

https://doi.org/10.35860/iarej.772678

Cited By: 1

Abstract

In industrialization, to be able to make cheap and fast production, assembly lines are one of the most basic elements in serial production systems. It is important to balance the assembly line to continue production smoothly. By assembly line balancing is created, each work step is grouped, stations are created and each station time is brought close to the station cycle times. In this study, a refrigerator top panel pressing line is analysed. The study’s aim is balancing the line for increase production rate. Firstly, the line is observed and some studies are planned. A time study is done to analyse the current situation of the line. Time study data are calculated by using Excel. Ranked Positional Weight Method is used as an intuitive method for single model U type assembly line balancing problem and mathematical modelling method is applied. The methods are used to balance the line using time study data. The solution of mathematical modelling is obtained by using Lingo. Results are compared and they are observed that results have almost the same. In conclusion, an assembly line balancing problem is mentioned in this study. Various programs related to the applied methods were used, and the data obtained as a result of current and final calculations were compared. First and last calculations and results are verified with each other. It was seen that the data obtained as a result of the study provided improvement.

Keywords

Assembly line balancing, Mathematical modelling, Ranked positional weight method, Time study, U-type line balancing problem

References

• 1. Li, M., Tang, Q., Zheng, Q., Xia, X., Floudas, C. A. Rules-based Heuristic Approach for the U-shaped Assembly Line Balancing Problem. Applied Mathematical Modelling, 2017. 48: p. 423-439.
• 2. Kilincci, O. Petri net-based algorithm for maximizing production rate in assembly lines. Journal of the Faculty of Engineering and Architecture of Gazi University, 2020. 35(2): p. 753-763.
• 3. Alagas, H. M., Yuzukirmizi, M., Turker, K., T. Stokastik Montaj Hatlarinin Kisit Programlama ve Kapali Kuyruk Aglari ile Dengelenmesi. Journal of the Faculty of Engineering Architecture of Gazi University, 2013. 28(2): p. 231–240.
• 4. Fathi, M., Fontes, D. B. M. M., Moris, M. U., Ghobakhloo, M. Assembly Line Balancing Problems: A Comparative Evaluation of Heuristics and a Computational Assesment of Objectives. Journal of Modelling in Management, 2018. Available from: https://doi.org/10.1108/JM2-03-2017-0027.
• 5. Boysen, N., Fliedner, M., Scholl, A. A Classification of Assembly Line Balancing Problems. European Journal of Operational Research, 2007. 183: p. 674–693.
• 6. Delice, Y., Aydogan, E., Ozcan, U. Stochastic Two-Sided U-Type Assembly Line Balancing: A Genetic Algorithm Approach. International Journal of Production Research, 2016. 54(11): p. 3429-3451.
• 7. Kayar, M., Akyalcin, Ö. C. Applying Different Heuristic Assembly Line Balancing Methods in the Apparel Industry and their Comparison. Fibres & Textiles in Eastern Europe, 2014. 6(108): p. 8-19.
• 8. Salveson, M.E. The Assembly Line Balancing Problem. Journal of Industrial Engineering, 1955. 6(3): p. 18-25.
• 9. Alagas, H. M., Pinarbasi, M., Yuzukirmizi, M., Toklu, B. Karma Modelli Tip-2 Montaj Hattı Dengeleme Problemi İçin Bir Kısıt Programlama Modeli . Pamukkale University Journal of Engineering Science, 2016. 22(4): p.340-348.
• 10. Nicosia, G., Pacciarell, D. Pacifici, A. Optimally balancing assembly lines with different workstations. Discrete Applied Mathematics, 2002. 118(2002): p. 99-113.
• 11. Helgeson, W. P., Birnie, D. P. Assem¬bly Line Balancing Using the Ranked Positional Weight Technique. Journal of Industrial Engineering, 1961. 12(6): p. 384-398.
• 12. Durmaz, H., Koyuncu, M. Optimization of Assignment Problems in Production Lines with Different Skilled Labor Levels. International Advanced Researches and Engineering Journal, 2019. 03(02): p. 123-136.
• 13. Islam, S., Sarker, S., Parvez, M. Production Efficiency Improvement by Using Tecnomatix Simulation Software and RPWM Line Balancing Technique: A Case Study. American Journal of Industrial and Business Management, 2019. 9: p. 809-820. Available from: https://doi.org/10.4236/ajibm.2019.94054.
• 14. Bongomin, O., Mwasiagi, J. I., Nganyi, E. O., Nibikora, I. Improvement of garment assembly line efficiency using line balancing technique. Engineering Reports, 2020. 2(5): p. 1-22. Available from: https://doi.org/10.1002/ eng2/ 12157
• 15. Ikhsan, S., Application of ranked positional weights method in springbed production line balancing. IOP Conf. Series: Materials Science and Engineering, 2020. 801. Available from: http://doi:10.1088/1757-899X/801/1/012098.
• 16. Niebel, W., Freivalds, A. ‘Time Study’, ‘Methods Standard and Work Design’. 2013, New York: The McGraw-Hill Companies, Inc. p. 415-449.
• 17. Salvendy, G. Handbook of Industrial Engineering, Technology and Operations Management. 3rd. edition. 2001, USA: John Waley & Sons, p. 2832.
• 18. Askin, R. G., Standridge, C. H. ‘Assembly Lines: Reliable Serial System’, ‘Modelling and Analysis of Manufacturing Systems’. 1993, USA: John Waley & Sons, p. 480.