The Modification and the Line Balancing of an Assembly Line for the Inclusion of a New Product Model

Abstract

This study aims to modify the 5th lean assembly line in order to include a new product model in a combi boiler producer company. After reviewing customers’ needs, company decides to produce a new product. New product model will be produced in the one of the existing lines in the plant. Most suitable line determined according to other product models job sequences’ similarity with new product models’. After the analysis of the production process, the changes and possible constraints for the 5th assembly line are determined. After that, solution procedures are developed, the required calculations are made and implemented. The solutions are developed by various techniques and approaches such as Bubble diagram, Value Stream Mapping, Lean Production, Line Balancing. Particularly, mathematical model, which is solved by IBM ILOG Optimization Studio programmed comprehensive analysis with a simulation model, which is conducted by Arena Simulation software, are presented in this study. The outcomes of the solutions are simulated, compared and automatized. At the end, three options are provided for the 5th lean line to include a new product type while continuing the production process with the current products.