Balancing the production line using the ergonomic approach

Abstract

Track balance is a process of balancing production lines at a series of work stations (machinery and equipment) that need to be carried out in the product manufacturing process. This aims of this research is to form and balance the work risks allocated to each work station. If the track balance is not carried out it can lead to inefficiencies and reduce the level of flexibility of the production floor. Job Rotation (JR) is a method for designing jobs where staff learn work skills from various parts and by making changes to tasks, fatigue resulting from repetitive work tasks will be eliminated. In principle, the Region Approach method seeks to charge first to operations that have a large preliminary responsibility. Through the research conducted, the optimum trajectory is obtained using the region approach and job rotation methods where the method can produce optimum work center and can reduce the risk of excessive work. Region approach trajectory, as many as 7 work stations. In addition, the efficiency of the production line where there is an increase in efficiency of 10.56% in the region approach trajectory. Then the balance delay decreased by 10.07% in the region approach trajectory, and a decrease in the smoothing index by 298.90 in the region approach trajectory. Based on the results of the calculation of work risk using the RULA method, the results of the calculation of work risk on the work elements of each work center where the results obtained by the reduction of work elements and the addition of work elements are carried out so that the work risks at each work center are balanced, and can reduce injuries when work. Production line on the proposed condition with a cycle time of 2304 seconds and there are 7 work stations. The known value of balance delay is 18.62%, efficiency is 81.76% and smoothing index is 2015.74.