Line Balancing Atlas Autos
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The document discusses line balancing of a rear cushion production line. It identifies bottlenecks in the current process with cycle times over the takt time of 10.1 seconds. By adding additional labor to two bottleneck stations, manual sub-assembly processes, the cycle times are reduced. This increases the minimum and maximum output capacities of the line to meet and exceed current and future demand. Line balancing the process eliminates idle time and improves productivity.
Line Balancing Atlas Autos
- 1. SUBMITTED BY: WAJAHAT ALI (BS IE, 4TH YEAR) SHAH FAISAL (BS IE 3RD YEAR ZAHOORULLAH (BS IE 3RD YEAR) MOHAMMAD IMRAN (BS ME 3RD YEAR) ADEEL KHALID (BS EE 3RD YEAR) ASIF NAWAZ( BS ME 2ND YEAR) LINE BALANCING OF REAR CUSHION LINE
- 2. LINE BALANCING Line balancing is the process of assigning tasks to workstations, so that workstations have approximately equal time requirements. We use line balancing to - minimize idle time - balance bottlenecks
- 3. BOTTLENECK Neck of the Bottle never has the same capacity as the base. In product layouts, when we want to improve productivity, we need to find and improve critical operations, known as bottlenecks. Productivity improvements to any non-bottleneck operation will NOT improve productivity of the system.
- 4. THE CUSHION SHOP The cushion shop has two lines operating: Front Fork Rear Cushion
- 5. CUSHION SHOP Total demand per shift= 2850 Total time Available= 575 min – Lunch Break= 30 min Prayer Break= 20 min Tea break= 20 min 5% tolerance time= 25.25 Total time for production=28785 sec= 480 min=8 hrs.
- 6. TAKT TIME Takt time= Production time available/Total demand per shift Takt time= 28785 sec/ 2850= 10.1 sec Thus one unit of product should spent a maximum of 10.1 sec in the line for producing 28750 units of production Total workstation are 11 and total man hours are 88.
- 7. REAR CUSHION All processes and their Cycle times in seconds
- 8. 3 Manual Sub- Assembly 4.1 Manual Sub assembly Riveting Oil seal press Rod Guide Press Caulking Stacking Sub- assy Sub- assy Sub - assy Metal Tightenin g Metal tightening 1 6 Inspectio n 1 6. 3 8. 5 3.6 10. 18 7.9 Sub-assy 10. 5 6.0 18 2.3 5 3.1 1 6.0
- 9. TABLE FOR CPM DIAGRAM Activity Alphabet Time Manual Sub Assy A 4.1 Manual sub Assy B 3.6 Manual sub assy+riveting C 8.5 Oil filling +rod guide press D 10.18 Stacking E 7.9 Manual sub assy+Caulking F 10.5 Manual sub assy G 6.018 Manual sub assy H 3.11 Manual sub assy I 2.35 Metal tightening (2 machines) J 8.1 Inspection k 6.032
- 10. CPM DIAGRAM A B C D E F G H IJK
- 11. GRAPH 0 2 4 6 8 10 12 Manual Sub assy Manual Sub assy Manual sub assy +riveting Oil filing+rod guide press Stacking Manual sub assy + caulking Manual Sub assy Manual Sub assy Manual Sub assy Metal Tighteining Inspection Time(sec)
- 12. THE BOTTLE NECK From the above data, it has been found that two processes in the line have appeared as Bottlenecks. The Combined process of oil filling and rod guide press are having the cycle times 10.18sec and 10.5 sec respectively. Thus the minimum cycle time of the line comes out to be 10.5 sec which is more than the takt time i.e. 10.1 sec.
- 13. OUTPUT CAPACITY Thus, maximum output capacity of line= Operating time /Min cycle time =28785/10.5= 2741 units The lead time or flow time of the line is 78.49 sec, which is also the maximum cycle time. Minimum output capacity of line= Operating time/ Max cycle time = 28785/78.49= 367 units
- 14. OUTPUT CAPACITY Thus the output capacity of current line can range from 367 units to 2741 units. But the requirement of line is 2850 units and even the max output capacity of line is not matching the demand and thus the workers of rear cushion are compelled to work in their lunch break and line’s speed is also increased at times. Thus the rear cushion line needs to be balanced.
- 15. ISSUES IN THE LINE At the combined process of oil filing+ rod guide process, the processing time is 10.18 sec. The product has to wait 2.4 sec on avg at the machine during the process. At the combined process of Caulking+ Manual sub assy, the processing time is 10.5 and the product has to wait 3.01 sec on avg at the machine during the process.
- 16. LINE BALANCING The bottleneck’s time should be reduced by increasing either machines or manpower. As both the bottlenecks include manual sub-assy, thus one more person should be added to these process. It will increase the workstations from 11 to 13. The processing time of both bottlenecks would be reduced by, one half.
- 17. TABLE FOR NEW CPM DIAGRAM Activity Alphabet Time Manual sub assy A 4.1 Manual sub assy B 3.6 Manual Sub assy+ Riveting C 8.5 Oil Filling+ Rod guide press D 5.09 Stacking E 7.9 Manual sub assy+ caulking F 5.25 Manual sub assy G 6.018 Manual sub assy H 3.1 Manual sub assy I 2.35 Metal Tightening( 2 Machines) J 16.2 Inspection k 6.032
- 18. A B C D E F G H IJK
- 19. GRAPH 0 1 2 3 4 5 6 7 8 9 Manual Sub assy Manual Sub assy Manual sub assy +riveting Oil filing+rod guide press Stacking Manual sub assy + caulking Manual Sub assy Manual Sub assy Manual Sub assy Metal Tighteining Inspection Time(sec)
- 20. PROCESS IMPROVEMENT Thus, the part waiting at the two bottlenecks processes is nullified now. The oil filling and rod guide process and caulking+ manual sub assy have the processing times 5.09 and 5.25 respectively. Now the min cycle time of the line is 8.5 sec which is the time of riveting+ manual sub assy, which is less than the takt time and thus the line is more balanced.
- 21. CAPACITY CALCULATION Now the maximum output capacity = Operating time/ min cycle time= 28785/8.5=3386 units The lead time or flow time of the line is 68.15sec, which is also the maximum cycle time. Minimum output capacity of line= Operating time/ Max cycle time = 28785/68.15= 422 units
- 22. ADVANTAGE Thus by balancing the line in this way, the line has the capacity to produce the parts in the range of 422 units to 3386 units and thus it has crossed the 2850 parts, daily requirement.
- 23. FUTURE USEFULNESS As currently the main frame line at the main plant is producing 1130 bikes everyday and the requirement from cushion shop is 2850. But with the installation of new line at the mainframe assembly, the requirement from cushion shop will rise.
- 24. CALCULATIONS 1130 bikes = 2850 cushions 1 bike= 2850/1130 cushions 1250 bikes= 2850/1130*1250 =3153 cushions.
- 25. CONCLUSION But if, the line will be balanced in the suggested way, then the maximum output capacity will be 3386 cushions and thus the cushion shop will not have to worry a lot on increase in demand from the mainframe assembly.
- 26. THANK YOU