Welcome to our Presentation

Course No: IPE3600Course Title: IPE Case Study

Submitted By Md. Abu Bakar Siddique Roll: 125029

3rd Year, 6th SemesterDepartment of Industrial & Production EngineeringRajshahi University of Engineering & Technology.

Submitted toSonia Akhter

Assistant ProfessorDept. of IPERUET, Bangladesh

Contents

Topics of our case studyIntroduction

ObjectiveProblem Definition

MethodologyMethods of Line Balancing

Assembly ShopData

Calculations & ResultsImprovement

Conclusion

1.Topics of the case study

“Study on improvement in Productivity

by developing an efficient Line Balancing at Runner

Automobiles Ltd.

1.Introduction

Introduction

Increasing productivity has become a buzz word nowadays on the basis of industry. There are several methods for increasing productivity and Line Balancing is one of them.

Increase in production volume by decreasing cycle time is the main task of line balancing.

There are 12 model motor bikes are manufactured by RAL and we chose Royal+ bike due to its attractive look and its high customer demand in the present market.

Literature Review

The Comsoal algorithm method of sequencing operation for assembly lines (Comsoal) was developed by Arcus. The production generates a large number of feasible solution using a simulation method.  The general algorithm of line balancing that we use for the further improvement was done by Panneerselvam, et, aL, 1993. This algorithm is used both in Rank positional method as well as in Comsoal algorithm method. The term idle time and down time are not included in this algorithm method which creates an error some results.  Swapnil T. Firake and Dr. K. H. Inamdar wrote a journal on the topics of “Productivity Improvement of Automotive Assembly Line through Line Balancing” where idle time, down time and a non-value added activity is taken into consideration. Muthanna Jamil and Noraini Mohd Razali wrote an journal on the topics of “Simulation of Assembly Line Balancing in Automotive Component Manufacturing” where an assembly line is developed on the basis of line balancing efficiency and minimum percentages idle time.

2.Objectives

Objectives

To study the current line balancing of Runner Automobiles Ltd.

Subdivide the network into several sub-networks. Precedence relationship of that sub-networks are not

violated. Allocating operation to each station without exceeding

the cycle time. Complete the assembly line with proper heuristics. Finding out the limitations of existing line and then give

a proper solution.

3.Problem Definition

Based on a preliminary study of the current production line there exist three major problems.

Firstly, the production rate is not in optimum level on the basis of cycle time. Secondly, the line is experiencing moderate line efficiency. Thirdly, the job rotation is very acute there and so the line is stopped uncertainly as the worker are not 100% expert.

We work for improvement in productivity by solving this situation applying the knowledge of line balancing.

Problem Definition

4.Methodology

5.Methods of Line Balancing

•Rank Positional Method•Comsoal Algorithm Method

Ways of finding out Line

Balancing:

Rank Positional Method:The ranked positional weight method was developed by Helgeson and Brinie. This method assigned those jobs first whose follower have the largest total time. The positional weight of a work element is its own processing time plus the processing times of all the following work elements.Comsoal Algorithm Method:This computer method of sequencing operation for assembly lines was developed by Arcus. The procedure generates a large number of feasible solutions using a simulation method.

Why Comsoal Algorithm is better than Rank positional method?

The two methods that mentioned are almost same in the sense of general algorithm. But the difference is in their condition. The main limitation of Rank Position Method is that the immediate predecessor are already assigned to some station on the contrary applying Comsoal Algorithm immediate predecessor are also already assigned but not in some station. That could be assigned in all stations or in no station. That’s the benefit of Comsoal Algorithm Method and so we choose this method for the further calculations.

6.Motor Bike Elements

Basic elements of Motor Bike

Wheel

Hydraulic plate of wheel

Saree guard

Muffler (Gas exposer)Handle bar

Mad guard

Basic elements of Motor Bike

Shock absorberChassis (Frame) Gear lever

Chain Chain guard Head light

Basic elements of Motor Bike

Head Speedometer (Tachometer) Side cover

Fuel tankSeat

Engine

7.Functions

Operation Number Functions

Pre-assembly – 01 Unpacking & placing of all parts.

Pre-assembly – 02 Joining hydraulic plate to wheel.

Pre-assembly – 03 Blowing air to wheel.

Pre-assembly – 04 Joining rubber to the mat-guard.

Pre-assembly – 05 Joining light to the mat-guard.

Pre-assembly – 06 Joining parts of handle bar.

Pre-assembly – 07 Joining parts of speedometer.

Pre-assembly – 08 Joining light to head.

Pre-assembly – 09 Preparation of chassis.

Pre-assembly – 10 Assembling engine to chassis.

Assigned tasks in pre assembly

Assigned tasks in assembly

Operation Number Function

Assembly – 01 Assembling shock absorber & front wheel.

Assembly – 02 Assembling chain & chain guard.

Assembly – 03 Assembling back wheel.

Assembly – 04 Assembling mat-guard Screw tightening.

Assembly – 05 Assembling handle bar.

Assembly – 06 Assembling muffler.

Assembly – 07 Assembling gear lever.

Assembly – 08 Assembling speedometer.

Assembly – 09 Assembling electric wire.

Assembly – 10 Assembling Head & pumping point.

Assembly – 11 Assembling seat lock and saree guard.

Assembly – 12 Assembling fuel tank cover.

Assembly – 13 Assembling side cover and seat.

8.Line Layout

Line Layout

Pre Assembly Section

Assembly Section

Precedence diagram

9.Operation time with predecessor

Operation No Duration (Sec) Immediate predecessor

PA 1 190 -- PA 2 55 PA 1PA 3 32 PA 1, PA 2PA 4 145 PA 1PA 5 150 PA 1, PA 4PA 6 137 PA 1PA 7 90 PA 1PA 8 100 PA 1PA 9 180 PA 1

PA 10 196 PA 1, PA 9A 1 210 PA 1, PA 2, PA 3A 2 60 PA 1A 3 120 PA 1, PA 2, PA 3A 4 118 PA 1, PA 4, PA 5A 5 140 PA 1, PA 6A 6 215 PA 1A 7 160 PA 1A 8 180 PA 1, PA 7A 9 193 PA 1

A 10 222 PA 1, PA 8A 11 167 PA 1A 12 130 PA 1A 13 109 PA 1

PA = Pre Assembly A = Assembly

10.Calculation

Production time = 6 hour 30 minute = 23400 secProduction volume = 100 unit/day for Royal+ bike Cycle Time = = = 234 Second

SUACT = 44 + 19 + 41 + 54 + 38 + 12 + 14 + 4 + 22 + 24 + 84 + 94 + 4 + 12 + 108 + 5 + 116

= 695 Sec Station Number = 17 Cycle Time = 234 Sec  Balancing efficiency

= (1 - ) * 100%

= (1 - ) * 100%

= 85% 

11.Improvement

Proposed Model 1On the basis of interchanging in assemble point

Assembly line

A2 A4 A9 A8 A11 A7 A12 A130

20406080

100120140160

0

100

2 7 13 13 7

3021

0

150

2 0 0

55 5537

21

Idle time vs Assembly line

Assembly points

Tim

eGraphical representation

Idle time of present assembly line

Idle time of proposed assembly line

Figure: Difference of idle between present and proposed Assembly line.

There is a chance of reduction of work station. Work station 17 is used for only Assembly point A4 (Assembling mat-guard Screw tightening). It takes in average 118 sec. if we could reduce it

to 108 sec by involving an extra worker

Assembly point Operation duration (Sec)

Corresponding sub-assembly

A4 118 PA1, PA4, PA5

This A4 assembly can be done in workstation 15 instead of workstation 17, if A4 = 108 seconds. If A4 = 108, then it can be carried in workstation 15, because workstation 15 has 108 SUACT. So let, A4 = 108 then

Balancing efficiency = (1 - 𝑆𝑈𝐴𝐶𝑇𝐶𝑇∗𝑆𝑁 ) * 100%

= (1 - 591−108234 ∗ 16 ) * 100%

= 87%

Proposed Model 2

11.Overview of the proposed model

Items Details Efficiency Maximum Idle time

Proposed model 1Three unites of workstation

addedIn A1 assembly point,

assembly line is redesigned.

94% 6%

Proposed model 2 Faster production in A4 assembly point. 87% 13%

Overview on proposed models

12.Conclusion

Conclusion

The goal of the line balancing is to make an efficient line to improve production volume from the existing production line. The assembly line needs to balance so that the line has the high value of efficiency. Higher value of line efficiency indicates that the line have the approximately equal cycle time between operators along the line. Besides that, the workload between operators also distributed equally which make the higher line efficiency. As Runner Automobiles Ltd is in premature age so the line balancing can bring a great help to increase the profit of the company. Finally the case study is successfully completed with the help of our honourable adviser Assistant Professor Sonia Akhter and we are really thankful to her.

13.Reference

References

Pannerselvam, R. 2013, Production and Operation Management, 3rd ed, PHI Learning Private Limited, Delhi – 110092, 219 – 240.

Firake, S.T & Dr. Inamdar, K.H, 2014, Productivity Improvement of Automotive Assembly Line Through Line Balancing, Volume 2, Issue 3 (May-June 2014), PP. 124-128

Jamil, M. & Rajali, N.M., 2015, Simulation of Assembly Line Balancing in Automotive Component Manufacturing

Thanks to all…

For contact: http://bit.ly/2fy1aizEmail: mabs.ipe12@yahoo.com