A NEW MODEL PROPOSAL FOR ERGONOMIC ASSEMBLY LINE BALANCING

Abstract

Assembly line balancing is a problem where tasks assign to stations in compliance with precedence constraints and as far as possible to balance delays. Assembly lines which is not designed properly in an ergonomic way cause not only productivity loss but also work-related muscoloskeletal disorders on workers. To prevent such problems, it should be aimed to catch acceptable level for each workstation’s risk score and assign ergonomic risks equivalently among workers. In this study, for assembly line balancing problem, a new model approach is tackled, which constitute stations by consider ergonomic risk scores in addition to cycle time and precedence constraints. In order to compare proposed model with a classical assembly line balancing technique, a performance criterion which is combination of cycle time and ergonomic risk score were defined. The developed model was applied in a factory’s oven assembly line. In the assembly line, task times were measured, precedence diagram was constructed and ergonomic risk levels were evaulated by using REBA method. When balancing lines with using Longest Operation Times technique, performance score was %25.61 but when it comes to balance with developed model performance score was obtained %18.25. It has been detected that developed model provides 7.41% improvement in line’s total performance.

Keywords

• Assembly Line Balancing,Ergonomic Risk Evaulation,REBA

ERGONOMİK MONTAJ HATTI DENGELEME İÇİN YENİ BİR MODEL ÖNERİSİ

Abstract

Montaj hattı dengeleme probleminde yapılacak işlemler, hattın belirlenen hızda devam etmesi amacıyla ve öncelik ilişkilerini dikkate alarak dengeli bir şekilde istasyonlara atanır. Montaj hattı ve istasyonların tasarımında ergonomik düzenlemeler göz ardı edildiğinde, çalışanlarda kas iskelet sistemi hastalıklarına ve devamında verimlilik kayıplarına da yol açabilir. Çalışan sağlığını ve üretimin verimliliğini korumak için montaj hattı dengelemede her bir istasyonun ergonomik risk düzeyinin kabul edilebilir seviyeye çekilmesi ve zorlanma düzeyinin işçiler arasında dengeli dağıtılması da amaçlanmalıdır. Bu çalışmada, montaj hattı dengelemede, öncelik ilişkileri ile çevrim süresi kısıtına ilaveten, ergonomik risk düzeyini de dikkate alan yeni bir model geliştirilmesi amaçlanmıştır. Ayrıca, önerilen modelin klasik montaj hattı dengeleme modeli ile karşılaştırılması amacıyla, süre ve ergonomik risk düzeyinin bileşkesinden oluşan performans ölçütü tanımlanmıştır. Geliştirilen model, bir işletmenin fırın montaj hattı için uygulanmıştır. Her iki montaj hattında işlem süreleri ölçülmüş, öncelik ilişkileri çıkarılmış ve REBA yöntemi ile ergonomik risk düzeyleri hesaplanmıştır. En Büyük Aday yöntemi kullanılarak yapılan klasik montaj dengelemede, performans skoru %25.61 olurken, geliştirilen model için %18.25 elde edilmiştir. Geliştirilen modelin, toplam performansda %7.41 iyileştirme sağladığı tespit edilmiştir.

Keywords

• Montaj Hattı Dengeleme,Ergonomik Risk Değerlendirme,REBA

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