Line Balancing Methods Research Articles

Optimizing the Queuing System at the Grogol Sukoharjo District Health Center Using the Line Balancing Method

The average number of patients served by the Grogol Health Center in the general polyclinic is 40 to 45 patients every day. Based on these data, there is a buildup of 7-10 patients, with an average service time of 10 minutes per patient. From the results of further observations, there is a buildup of patients in the general polyclinic of the Grogol Health Center. This study aims to solve the queue problem with the line balancing method and develop an online registration application at the Grogol Health Center that can increase the efficiency of the patient registration process and reduce waiting time. Line Balancing is a method for solving queue system problems. So that the results of this study are the creation of an integrated application and online registration that can reduce waiting time

Analisis Efisiensi Waktu Siklus Untuk Meningkatkan Produktivitas Dengan Line Balancing Pada Proses Pengemasan Produksi Obat Diabetes di PT.OPQ

Operation Excelence is needed at manufacturing process in order to achive optimum cost. One of method is using line balancing. It work by increasing efficiency and remove bottole neck at workstation.. The purpose of this research is to increase productivity in the work path of diabetes drug production line, it means that all work stations can achieve optimum output, eliminate or reduce material accumulation by identifying line balances at work stations. By using the Line Balancing method. The method used is the Ranked Position Weight (RPW) heuristic method. As result productivity was increasing, with line efficiency from 58.36% to 80.25%, balance delay from 41.64% to 19.75%, a decrease in the amount of material accumulation between work stations on the diabetes drug production trajectory from 25 - 1175 doos / hour to 4 - 174 doos / hour, and eliminating the bottleneck on the trajectory of diabetes drug production.

Usulan Perancangan Tata Letak Fasilitas pada Pembuatan Kulit Kebab Tortila Guna Meminimalisir Jarak Material Handling dan Meningkatkan Output Produksi (Studi Kasus: PT Tamma Robah Indonesia)

PT Tamma Robah Indonesia is a company operating in the manufacturing industry which produces kebab tortilla shells, the types of products produced by PT Tamma Robah Indonesia are TB (Large Tortilla), TS (Medium Tortilla), TM (Mini Tortilla), TC (Tortilla Catering). This research method uses the line balancing method which aims to obtain a smooth production flow in order to obtain high utility for facilities, labor and working time as well as simulating the production flow process, distance and increasing production output using flaxim software development to maximize the implementation of relayout. . Based on the results of the analysis of the research objectives carried out, it can be concluded that the line balancing calculation of the 4 products produced by PT Tamma Robah Indonesia selected the lowest Tortila Catering process distance with a cycle time of 130 seconds. /pcs, with 3 work stations, efficiency and delay 23%. and there are several proposed layouts that can minimize material handling distances.

ANALISIS LOADING TIME HIKITORI MENGGUNAKAN METODE LINE OF BALANCING

In this research, there is a problem about hikitori cycle process through the use of line balancing method, which is able to reduce long loading times become faster. The main objective of this research is to reduce hikitori loading time by using line of balancing, which will later produce new planning with more efficient process. The term hikitori is not common for all industries, but Japanese companies often use naming standards and work culture input in the industry. One of the industries originating from Japan is hikitori, namely vehicles that transport goods that will or have been processed. So that, going through the line balancing stage process makes the hikitori productivity system easier, which happens due to the preparation of the hikitori line with the addition of a new production line with a cycle time of 30 minutes, and the graphic visualization shows the problem where the waiting time becomes 89.5 minutes of the total MP, causing the total actual sigma CT is 323 minutes for a total of 10 MP. The research results show that there is a reduction in job balancing, thereby reducing time to 9 MP and waiting time also decreases to 9 MP or 22 minutes.

Optimalisasi Line Balancing Menggunakan Metode Ranked Positional Weight, Moodie Young, dan J-Wagon

Cahaya Furniture is an industry engaged in Furniture, which is located in Kampung Jua, Lubuk Begalung Nan XX District. In the teak cupboard production process, there is an imbalance in the teak cupboard production. This study aims to deterine the performance of the production line balance using the Ranked Positional Weight, Moodie Young, and J-Wagon methods. The results show that the current track efficiency is 76.83%, Balance Delay is 32.17%, Smoothness Index is 36.13 with 5 work stations, whereas after calculating with the Line Balancing method, the result is that using the Ranked Positional Weight method the increased efficiency value increased to 96.04%, the balance delay decreased to 3.96%, the smoothness index was 5.32 with withdrawals being 4 work stations. In the Moodie Young method, the recovery efficiency value is the same as the initial condition, which is 76.83%, the balance delay is 23.17%, the smoothness index is 14.39 with 5 work stations. In the J-Wagon method, the track efficiency value decreased to 64.03%, the balance delay increased to 35.97%, the smoothness index was 19.65 with 6 work stations. The results of this study indicate that the most effective method used is the Ranked Positional Weight method because there is a reduction in work stations to 4, and increases transfer efficiency to 96,04%, decreases balance delay from 3.96%, and smoothness index decreases to 5.32.

Study of a Sewing Line of an RMG Factory and Productivity Improvement through Line Balancing

The RMG industries play a major role in the economic development of Bangladesh. However, in the current business environment, like every other country all over the world, this sector also faces some troubles related to resource constraints like time, cost, materials, etc. So, to ensure the sustainability and competitiveness of the RMG industries of Bangladesh, productivity improvement becomes the key factor. For this reason, this research aims to measure and improve the productivity of other performances of a sewing line of a selected RMG industry. This study uses time study, expert opinions, and the line-balancing method. This research finds that before improvement in the line efficiency, total idle time, and the number of workstations is 43.04%, 9.401 minutes per cycle, and 19 respectively. But after improvement in the line efficiency, total idle time and number of workstations become 81.78%, 1.6087 minutes per cycle, and 10 respectively. Thus, the findings of this research prove that implementing a line-balancing strategy in the sewing section of RMG industries can boost productivity. So, this research can be useful for other RMG industries for future implementation.

Line Balancing Based on Error Rate Estimation with Artificial Neural Networks in Assembly Line Operations

In this study, in the assembly line systems consisting of the operations in interaction with each other; To reduce the number of faulty products, to prevent poor quality and to reduce the production time, Error Ratio Estimation with Artificial Neural Networks and probabilistic Line Balancing method have been performed. The error rate estimation provides information on which jeans models should be applied in the improvement work to eliminate existing errors in place. In the study, using the Levenberg - Marquardt Learning Algorithm, machine learning was determined by the experimental design method. At the same time, it has been used as an artificial intelligence algorithm in the multi-directional decision making stages, estimation and line balancing parts. In Assembly Line Equilibration, it has been aimed to re-stabilize the unbalanced line with the influence of post-forecasting process recovery. The Probabilistic Line Balancing method has been used because the processing times are stochastic (variable) and statistical data and mathematical algorithms (digital algorithms can be created). When the results are examined, a successful forecasting process has been carried out for two different five-pocket jeans models which has been selected and it has been seen that the work components of the probabilistic line balancing method enable it to be precisely assigned to work stations. And it has given reliable results.

Line Balancing Method As An Effort To Improve Cable Production In Pt Kmi Wire And Cable Production Management

Write Line Inner Sheating at PT. KMI Wire and Cable has idle time due to processing time on Unbalanced work stations sometimes cause stop lines. Fromcalculations it is known that the cycle time gap / cycle time obtained is as big as 109.2 seconds and the figure is taken based on the biggest time from 6 stations existing work. The author intends to examine the causes of its occurrence processing time delays that occur on the Inner Sheating line and deliver give suggestions for future improvements. This research uses line balancing method and production system layouts. Among them is looking for the cycle time at the 6 largest stations as a reference in determining the next calculation, calculating the company's capacity, determining the efficiency of the machine, calculating the number of machines, adding the number of machines and additional floor area. Data is taken from field observations and records. The author uses two methods, namely the line balancing method and the system method production layout. he line balancing method and production layout system that has been carried out can be causing it to be able to meet market demand of 17,688 coils / month with the addition of machines / work stations, the required floor area is 14 m² with details, 7 m² at the Inner Sheat workstation and 7m² at the Outer Sheat station.

Application of Heuristic Assembly Line Balancing Methods to Lighting Automation Industry

The assembly line balancing problem is an important issue for every manufacturing company. A balanced assembly line ensures that a product is produced in the optimum time, and as a result of this effect, less machinery, materials and labour are used during this production. In this article, theoretical information about assembly line balancing has been given, and then the data needed for assembly line balancing has been obtained by making a time study of the production of Downlight Luminaire. With these data obtained, assembly line balancing was done and compared by using Hoffman and Comsoal methods. The aim of this study is to investigate the applicability of Hoffman and Comsoal methods, which are one of the heuristic assembly line balancing methods, in the assembly lines of the companies producing in the lighting sector.

Towards gestured-based technologies for human-centred Smart Factories

ABSTRACT Despite the increasing degree of automation in industry, manual or semi-automated are commonly and inevitable for complex assembly tasks. The transformation to smart processes in manufacturing leads to a higher deployment of data-driven approaches to support the worker. Upcoming technologies in this context are oftentimes based on the gesture-recognition, − monitoring or – control. This contribution systematically reviews gesture or motion capturing technologies and the utilization of gesture data in the ergonomic assessment, gesture-based robot control strategies as well as the identification of COVID-19 symptoms. Subsequently, two applications are presented in detail. First, a holistic human-centric optimization method for line-balancing using a novel indicator – ErgoTakt – derived by motion capturing. ErgoTakt improves the legacy takt-time and helps to find an optimum between the ergonomic evaluation of an assembly station and the takt-time balancing. An optimization algorithm is developed to find the best-fitting solution by minimizing a function of the ergonomic RULA-score and the cycle time of each assembly workstation with respect to the workers’ ability. The second application is gesture-based robot-control. A cloud-based approach utilizing a generally accessible hand-tracking model embedded in a low-code IoT programming environment is shown.

Optimizing the Material-Product Transformation Processes in the Clothing Manufacturing Line

In current economic conditions, one of the major problems in the textile and apparel industry is unable to determine the unnecessary movements of resources (operators, machines, materials). Especially during the production processes, to adjust and decrease the movements of the resources are more difficult, because the focus is mostly on the workers and materials. “Method Study” has developed for resolving these challenges. The string diagram which is one of the techniques of the method study, helps to provide minimum movements of the resources during manufacturing activities. In this study, the production activities of a clothing company were examined with the help of the string diagram to achieve the objectives of eliminating unnecessary movements of the resources, increasing the working speed, providing better working conditions, balancing the production lines. So in the study, the current status of the production system and the parts to be improved were determined. In this direction, the string diagram and line balancing methods were applied for improvements and generation of a new layout plan. As a result of the research, the journal distance of the pieces before sewing together for obtaining the end product was shortened by 39% and the number of operators working in the line was reduced from 32 to 26.

Researching the Optimal Method of Balancing the Sewing Line with T-Shirt Product in the Garment Industry in Vietnam

The garment industry is currently one of the largest industries in Vietnam. In 2021, Vietnam became the second-largest garment exporter in the world after China. Towards decent work and economic growth, garment businesses in Vietnam are very interested in improving productivity and quality, one of the measures is balancing the sewing line. Currently, Vietnamese garment enterprises mainly use the method of line balancing according to experience, leading to the low line balancing efficiency, the line balancing performance is not stable, and the transfers of the semi-finished products between working positions are not optimized. Utilizing the theoretical basis of methods of line balancing, the level of balance of the sewing line has been researched, calculated, and compared based on the evaluation criteria to find the most optimal method. In this research, 5 methods of balancing line are used to balance the t-shirt sewing line in the garment industry in Vietnam and found the most optimal method in 5 methods.

Layout Planning For Production Facilities Using Line Balancing and ARC (Activity Relation Chart) Methods at UD. Agung Mulya

Agung Mulya has experienced a decline in the production process, because there is an inefficient machine arrangement that causes delays in producing products, products with a target in a day can produce about 300 pcs of requests, can only produce about 170 pcs of requests, it is suspected that the main cause is the layout of the machine. less precise. In an effort to solve this problem, this study uses a method using Line Balancing and ARC (Activity Relation Chart) methods. This method is used for structuring the production flow so that there is a balance on all production lines so as to provide high efficiency on each production line. The balance in question is the balance of output from each stage of operation from the point of view of the production line and compiling a layout design for room facilities is used to analyze the proximity relationship using input data in the form of process flow, distance between spaces, conditions and spatial conditions From the results of this study resulted in a better re-lay out of thr production facility layout, the work station which originally had 8 workstations has decreased to 5 workstations, this is because the layout of the production flow layout can reduce the distance between work stations and the production process more efficient.

Analisis Line Balancing pada Proses Produksi Style Order Long Pants

Line balancing is an assignment of a number of jobs into interconnected work stations in one production line. PT PB Tbk. is a company engaged in garment industry producing apparel. One of the products is long pants, there are 137 work elements which are divided into 4 work stations, where each work element consists of 1 operator. During production process, unbalance workload problems often occur such as a lot of idle time for some operatorsand overload for other operators. Based on this issue, it is necessary to recalculate the number of work stations and distribute the workload to avoid excessive idle time so that work can be more effective and efficient. One way to overcome this problem is applying line balancing method, with the aim that implementation of this line balancing method may achieve optimal results and each work station works effectively and has maximum work efficiency. The results of this study showed that there were additional work stations from 4 to 57, however there were adjustments to the workload.
 Keywords: line balancing, work station, bottleneck, work elements, efficiency

Improving Work Efficiency and Productivity with Line Balancing and TPS Approach and Promodel Simulation on Brush Sub Assy Line in Automotive Companies

From Gaikindo’s data, the impact of the covid-19 effect caused the automotive industry to experience a 50% contraction; PT Denso Indonesia, which is an automotive component company, felt the impact where actual production fell by 30% in the first quartile of 2020, the company’s adaptation was efficiency and productivity and activity cost down. The problem with the starter line is that there is a difference in the cycle time of each post in the sub-assy starter brush line, too gaping. From this problem, the researchers analyzed with the TPS and Line Balancing methods with the help of pro model simulations, from these activities evaluated the performance line from the previous line efficiency of 89.05% Balance Delay: 10.95% and Smoothie Index 12.58 improved to line efficiency of 93.59% Balance Delay: 6.35% and Smoothie Index 6.10. However, there are still bottlenecks, following which improvements will be made using line balancing with pro model simulations; pro model simulations were chosen because to make repairs, it is enough to use the help of applications that are in line with the goals of the company, which is currently survival amid this intense competition. After the repair was done using the Helgerson Bernie approach, a simulation of the line balancing method improvement was carried out. The line efficiency value was 95.76% Balance Delay: 4.24% and Smoothie Index 4.45 with a total outflow of 131 units of goods every 1 hour.

ErgoTakt: A novel approach of human-centered balancing of manual assembly lines

Although the increasing use of automation in industry, manual assembly stations are still common and, in some situations, even inevitable. Current practice in manual assembly lines is to balance them using the takt-time of each workstation and harmonize it. However, this approach mostly does not include ergonomic aspects and thus it may lead to workforce musculoskeletal disorders, extended leaves, and demotivation. This paper presents a holistic human-centric optimization method for line balancing using a novel indicator ̶ the ErgoTakt. ErgoTakt improves the legacy takt-time and helps to find an optimum between the ergonomic evaluation of an assembly station and its balance in time. The authors used a custom version of the ErgoSentinel Software and a Microsoft Kinect depth camera to perform online and real-time ergonomic assessment. An optimization algorithm is developed to find the best-fitting solution by minimizing a function of the ergonomic RULA-value and the cycle time of each assembly workstation with respect to the worker's ability. The paper presents the concept, the system-setup and preliminary evaluation of an assembly scenario. The results demonstrate that the new approach is feasible and able to optimize an entire manual assembly process chain in terms of both, economic aspects of a well-balanced production line as well as the ergonomic issue of long term human healthy work.

REDESIGNING ASSEMBLY LINE BY APPLYING RANKED POSITIONAL WEIGHT AT HEAVY-INDUSTRIAL FACILITY

To meet customer demand, the company was faced with insufficient capacity problems caused by low efficiency and congestion on the assembly line. Recent data shows that there is an imbalance in the work process time between workstations. This study aims to solve these problems to achieve the desired capacity. The research begins by observing the operating time and collecting other data on the assembly line then analyzed and developed as a solution to these problems. The analysis results show that the assembly line has low line efficiency and the impact on the output target is not as expected. From the time observations made on the assembly line, it can be seen that the current line is inefficient and there is a bottleneck at some workstations. Ranked Positional Weight (RPW) was chosen as a line balancing method to solve the problem. RPW generates new work arrangements for each workstation that has relatively the same uptime. The results of the RPW method showed a significant increase in line efficiency, namely 75.03%, the smoothness index increased by 90.79%, and the balance delay was reduced by 90.52%. After the solution is obtained, a new layout is created to be used as a guide for rearranging the assembly line.

Increased line efficiency by improved work methods with the ECRS concept in a washing machine production: a case study

The Assembly line is the assembly process that is carried out based on the order of the production process in the production line. The problem that is often found in assembly lines is bottleneck conditions where some material piled up at the station. This situation indicates an imbalance in the production line. The improvement of the work method is one of the effective ways that can increase line efficiency. This study presents an increase in line efficiency by improving working methods in a washing machine assembly line of PT.X. The study aimed to increase the value of line efficiency by improving work methods. In this study, improvements were made using the line balancing method and Eliminate, Combine, Rearrange, Simplify (ECRS) concept. The results that have been done, the obtained value of line efficiency for washing machine products is 76.76%. This value has not reached the company's productivity target of 99.50%. Therefore it is necessary to improve the assembling line to increase the value of product production. The proposed improvements made with improvements to the work methods on the assembling line obtained 89.38% results is to increase the amount of line efficiency by improving work methods.

Calculation of Labor Amount with Theory of Constraints and Line Balancing Method in PT. XYZ Fish Crackers Factory

The right amount of labor on work station is important to avoid uneven workload, that might reduce efficiency on production line, and cause bottleneck. Therefore, this research focus at searching the optimal amount of labor using line balancing and bottleneck that occurs on XYZ Fish Crackers Factory. Theory of constraints method is used to identify bottleneck, and line balancing method that will be used is Kilbridge-Wester, Moodie Young, Helgeson-Birnie, and J-Wagon. Fish cracker drying is the process that encounter bottleneck. The beginning line efficiency is 50.09%, with Kilbridge-Wester, Helgeson Birnie, and J- Wagon method, the line efficiency is 89.22%, and with Moodie Young method, the line efficieny is 89.45%. Therefore, Moodie Young method is the best method to apply, because it has the best result, with 89.45% line efficiency, 10.55% balance delay, 13.96% smoothness index, 20.3 minutes of idle time, 5 work station, and amount of labor needed is 10 person.

Evolutionary optimization using epsilon method for resource-constrained multi-robotic disassembly line balancing

This paper concentrates on a resource-constrained multi-robotic disassembly line balancing (RC-MDLB) problem. In this RC-MDLB problem, different types of end-of-life products are disassembled simultaneously on the same line under the following conditions: allocating multiple robots to a workstation to simultaneously process the disassembly tasks that have no precedence relationship with each other, each robot needs a fixed number of limited resources to process tasks, and the total resources for each workstation is fixed. A mathematical model is presented for the RC-MDLB problem to minimize the cycle time and the number of robots being occupied simultaneously. A constrained multi-objective evolutionary algorithm framework and a constrained NSGA-II (E-NSGA-II) algorithm with epsilon method are proposed to handle the constraints of the RC-MDLB problem. The proposed E-NSGA-II is applied to a set of RC-MDLB problem instances introduced in this paper and compared with five representative multi-objective evolutionary algorithms. The experimental results reveal that the proposed E-NSGA-II presents outstanding performance on most of the cases analyzed.