Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
COMPANY NAME
INTRODUCTION
Project Background
Title of this project is Johnson Electric DC Motor CG605-60001 Line Balancing Project. It is a study
to improve the cycle time of each of workstations and to reduce bottleneck that will affect the output capacity.
By reducing the bottleneck, labour efficiency can be increased which will affect to the lower operation cost and
increase the line capacity and also achieving demand. In other words, total productivity can be increase due to
constant input but increase in output. This is the key performance indicator to a manufacturing company that
shows their performance and ability to meet customer expectations.
Layout decision is an important concept that need to be look at. Decision to setup a production layout
in a manufacturing company need to consider on the space availability, equipment to be installed, headcount
required, material movement and the product itself. The layout determined the capability and efficiency of a
company in a long run. The objectives of layout strategies are to develop an effective and efficient layout so
that meet customer demand and aligned with the business scope and requirement. There are many types of
layout such as office layout, retail layout, warehouse layout, fixed-position layout, process-oriented layout,
work-cell layout and product oriented layout.
Repetitive or product oriented layout was applied to the production line of the Johnson Electric DC
motor due to high volume of demand and low product variety. There are two types of product oriented layout
which is fabrication lines and assembly line. Our project is related on assembly line that having series of work
stations. Problem occurs when the demand increase while the output cannot meet the demand even though
based on calculation of the TAKT time, the line have the capability to meet them. Hence, problem found that
the cycle time of some work stations is exceeding the TAKT time, which shows there is opportunity of
improvement.
Even though the product oriented layout is suitable for high volume of output, there is some
2.
3.
Any issue on the particular work station can affect the whole production rate or line jerk.
COMPANY NAME
Problem Statement
In conjunction of achieving efficiency in manufacturing operation to have higher return with maintain or
reducing the fixed and variable cost, analysing and segregating the assignment of tasks is being focussed. The
workload or task need to be levelled to remove bottleneck and increase the line capacity. Line balancing was
implemented to have better and balance of cycle time so that it not exceed the TAKT time. There is some
problem faced on doing the line balancing on this project and the constraint is as below.
1.
Unable to disclose real time data due to data confidentiality of the organisation
2.
Current layout is in a repetitive straight line with a shortage of 2 operators making the time study
collection data hard. This assumption will be modelled during the analysis phase.
Objectives
There is some objectives that need to achieved on executing the line balancing project for Johnson
2.
3.
Project Scope
The project scope for this line balancing project is to purpose and introducing line balancing process in the
manufacturing process of the Johnson Electric DC Motor CG605-60001. This project will improve the output
of the production line and balance the segregation of the process so that bottleneck can be reduced.
LITERATURE REVIEW
Line Balancing means balancing the production line, or any assembly line. The main objective of line balancing
is to distribute the task evenly over the work station so that idle time of man of machine can be minimized.
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.
Assembly Line Balancing (ALB) is the term commonly used to refer to the decision process of assigning tasks
to workstations in a serial production system. The task consists of elemental operations required to convert
raw material in to finished goods. Line Balancing is a classic Operations Research optimization technique
which has significant industrial importance in lean system. The concept of mass production essentially involves
the Line Balancing in assembly of identical or interchangeable parts or components into the final product in
various stages at different workstations. With the improvement in knowledge, the refinement in the application
of line balancing procedure is also a must. Task allocation of each worker was achieved by assembly line
balancing to increase an assembly efficiency and productivity.
I.
Line Balancing
Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks
and excess capacity. A constraint slows the process down and results if waiting for downstream operations
and excess capacity results in waiting and absorption of fixed cost.
II.
In early times assembly lines were used in high level production of a single product. But now the products will
attract customers without any difference and allows the profitable utilization of Assembly Lines. An advanced
technology of production which enables the automated setup of operations and it is negotiated time and
money. Once the product is assembled in the same line and it wont variant the setup or significant setup and
its time that is used, this assembly system is called as Single Model Line. C Merengo, F Nava, A Pozzetti
(1999)
III.
In this model the setup time between the models would be decreased sufficiently and enough to be ignored.
So this internal mixed model determines the assembled on the same line. And the type of assembly line in
which workers work in different models of a product in the same assembly line is called Mixed Assembly Line.
IV.
In this model the uniformity of the assembled products and the production system is not that much sufficient
to accept the enabling of the product and the production levels. To reduce the time and money this assembly
is arranged in batches, and this allows the short term lot-sizing issues which made in groups of the models to
batches and the result will be on the assembly levels.
V.
g. Waiting
If line is not properly balanced and inappropriate material flow selection are the reasons behind waiting time.
The time spent on waiting for raw material, the job from the preceding work station, machine down-time, and
the operator engaged in other operations and schedules are the major contributors in the waiting time.
VI.
i. Cycle Time
Cycle time is the Maximum amount of time allowed at each station. This can be found by dividing required
units to production time available per day. Waldemar Grzechca (2011)
iii. Bottleneck
Delay in transmission that slow down the production rate. This can be overcome by balancing the line.
iv. Precedence
It can be represented by nodes or graph. In assembly line the products have to obey this rule. The product
cant be move to the next station if it doesnt complete at the previous station. The products flow from one
station to the other station, M E Salveson I (1995). A typical precedence diagram is mentioned in Fig.4 below
to represent the activities.
RESEARCH METHODOLOGY
Eciency
The efficiency of an assembly line can be determined via :
Using this efficiency formula, a firm can determine the sensitivity of the line to changes in production rate and
workstation assignments
Step 1
Specify the sequential relationships among tasks using a precedence diagram. The diagram consists of circles
and arrows. Circles represent individual tasks; arrows indicate the order of task performance.
Step 2
Determine the required cycle time (C), using the formula:
Step 3
Determine the theoretical minimum number of workstations (Nt) required to satisfy the cycle time constraint
using the formula:
Step 4
Select the following heuristics rules as primary and secondary rules to assign the tasks to workstations, As
defined by (Heizer, Jay , 2014) :
Rules
Longest Task (Operation) time
Definition
From the available tasks, choose the task with the
longest processing time
Step 5
Assign tasks, one at a time, to the first workstation until the sum of the task times is equal to the cycle time, or
no other tasks are feasible because of time or sequence restrictions. Repeat the process for Workstation 2,
Workstation 3, and so on, until all tasks are assigned.
Step 6
Evaluate the efficiency of the balance derived using the formula:
Step 7
If efficiency is unsatisfactory, rebalance using a different decision rule. The decision rules can be suggested as
follows:
2.
3.
4.
Determine the theoretical no of work stations (Nt = Sum of the task times/cycle time)
5.
Select a rule which tasks are to be assigned to work stations and a secondary rule to break the ties.
6.
DATA COLLECTION
The DC Motor
Johsons CG105-60001 motor is a two stage stepper motor that is being used for major electrical appliances
that are in the market now. This is due to the modular design of the motor using shared components withs its
predecessor motors.
Qty
Description
Motor Housing
Magnet
Magnet Holder
Magnet Spring
Steel Shaft
10
Commutator
11
12
Sleeve Bushing
13
Carbon Brush
14
Terminal
15
Brush Spring
16
Brush Holder
17
Metal Endcap
A time study was conducted to collect the time needed for each process that is in the assembly line. The time
was recorded using a time study template & a digital stop watch as per the picture below :
Elements
Work Element
Description
Seconds
Minutes
Preceded By
Load 1
0.0333333333333333
Grease inside 1
45
0.75
Place 2 in 1
10
0.166666666666667
Place 4 & 5 in 3
0.133333333333333
Load 6 into 8
27
0.45
0.116666666666667
Load 10 & 11
25
0.416666666666667
0.116666666666667
0.0833333333333333
10
Load 15 into 13
41
0.683333333333333
11
0.0833333333333333
10
12
10
0.166666666666667
8,11
13
50
0.833333333333333
12
14
10
0.166666666666667
13
15
Combine 4,5,15,16,17
into 6&8
0.05
14
4.25
Precedence Diagram
The precedence diagram for the current manufacturing line is as below :
Elements
Seconds
Preceded By
13
50
12
14
10
13
15
14
45
10
27
25
10
41
11
10
12
10
8,11
Stat No
Total Time
65
63
66
61
Station 2
In
Station 1
Station 3
Out
Station 4
Eciency
The ranked positional weight method used and computed for each element. From the list of tasks, we need to
choose the task for which the sum of times for each following task is longest.
Elements
Seconds
Preceded By
45
10
27
25
10
41
11
10
12
10
8,11
13
50
12
14
10
13
15
14
Stat No
Total Time
65
66
61
63
Since circle layout was used previously, we have used a straight line layout for this instead.
In
Station 1
Station 2
Station 3
Station 4
Out
Eciency
Efficiency is calculated as : 4.25/(4x1.1)= 96%
CONCLUSION
This study proposed three facilities designs in which the Johnson Motors DC Motor is to be assembled.
Moreover the author developed two assembly line processing layouts following the single straight line, & circle
processing Rank Positional Weight & Longest Task time respectively.
It ultimates the rate of production in the two approaches .This is to determine which layout can provide better
performance .The best layout of product found is the line stations is both for RPW & LTT method. Both the
layouts gives an efficiency of 96%. But the author will strongly suggest the implementation of the circle layout
due to its advantages over a straight line layout.
REFERENCES
1. C Merengo, F Nava, A Pozzetti Balancing and sequencing manual mixed-model assembly lines
International Journal of Production Research 37 (12) pp. 2835-2860.(1999).
2. Waldemar Grzechca Cycle Time in Assembly Line Balancing Problem journal of industrial engineering,
pp. 171-174,(2011).
3. M E Salveson The assembly line balancing problem Journal of Industrial Engineering Volume: 6,
Issue: 3, pp. 18-25,(1995).