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1 – 10 of over 52000
Article
Publication date: 25 December 2023

Zihan Dang and Naiming Xie

Assembly line is a common production form and has been effectively used in many industries, but the imprecise processing time of each process makes production line balancing and…

Abstract

Purpose

Assembly line is a common production form and has been effectively used in many industries, but the imprecise processing time of each process makes production line balancing and capacity forecasting the most troublesome problems for production managers. In this paper, uncertain man-hours are represented as interval grey numbers, and the optimization problem of production line balance in the case of interval grey man-hours is studied to better evaluate the production line capacity.

Design/methodology/approach

First, this paper constructs the basic model of assembly line balance optimization for the single-product scenario, and on this basis constructs an assembly line balance optimization model under the multi-product scenario with the objective function of maximizing the weighted greyscale production line balance rate, second, this paper designs a simulated annealing algorithm to solve problem. A neighborhood search strategy is proposed, based on assembly line balance optimization, an assembly line capacity evaluation method with interval grey man-hour characteristics is designed.

Findings

This paper provides a production line balance optimization scheme with uncertain processing time for multi-product scenarios and designs a capacity evaluation method to provide managers with scientific management strategies so that decision-makers can scientifically solve the problems that the company's design production line is quite different from the actual production situation.

Originality/value

There are few literary studies on combining interval grey number with assembly line balance optimization. Therefore, this paper makes an important contribution in this regard.

Details

Grey Systems: Theory and Application, vol. 14 no. 2
Type: Research Article
ISSN: 2043-9377

Keywords

Article
Publication date: 3 February 2012

Jose Arturo Garza‐Reyes, Ilias Oraifige, Horacio Soriano‐Meier, Paul L. Forrester and Dani Harmanto

Continuous process flow is a prerequisite of lean systems as it helps to reduce throughput times, improve quality, minimize operational costs, and shorten delivery times. The…

1533

Abstract

Purpose

Continuous process flow is a prerequisite of lean systems as it helps to reduce throughput times, improve quality, minimize operational costs, and shorten delivery times. The purpose of this paper is to empirically demonstrate the application of a methodology that combines a time‐based study, discrete‐event simulation and the trial and error method to enable a leaner process through more efficient line balancing and more effective flow for a park homes production process. This method is replicable across other contexts and industry settings.

Design/methodology/approach

The paper reviews the UK park homes production industry and, specifically, a major factory that builds these homes. It compares the factory method to traditional on‐site construction methods. An empirical study of production times was carried out to collect data in order to analyse the current workload distribution and the process flow performance of the park homes production process. Finally, seven discrete‐event simulation models were developed in order to test different scenarios and define the optimum line balance for every section of the production process.

Findings

By combining time study, discrete‐event simulation and trial and error methods, the workload distribution and process flow performance of the park homes production line were analysed and improved. A reduction of between 1.82 and 36.32 percent in balancing losses in some sections of the process was achieved.

Practical implications

This paper supports current knowledge on process flow improvement and line balancing by exploring and analysing these issues in a real‐life context. It can be used to guide production management practitioners in their selection of methods and demonstrates how they are exploited when seeking to improve process flow, efficiency and line balancing of production operations.

Originality/value

The study uses a real industrial application to demonstrate how the methodological combination and deployment of process flow improvement strategies, such as time study, simulation, and trial and error, can help organisations achieve process flow improvements and, as a consequence, a leaner production process.

Details

Journal of Manufacturing Technology Management, vol. 23 no. 2
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 1 January 2006

Syed Masood

This paper presents an investigation on the line balancing of an automated cylinder block production transfer line in order to reduce the total cycle time and increase machine…

2855

Abstract

Purpose

This paper presents an investigation on the line balancing of an automated cylinder block production transfer line in order to reduce the total cycle time and increase machine utilization in an automotive plant. Results were verified by computer simulation, which showed increased throughput and higher machine utilization as a result of line balancing.

Design/methodology/approach

Three main operation lines of the transfer line were identified as critical and having the highest cycle time and were chosen for optimisation study. Strategies of re‐sequencing of existing operations and tools were used to reduce the cycle time of these critical operations and to balance the line. Results of a simulation study using Simul8 software are also presented to demonstrate the increase in machine utilisation and throughput as a result of line balancing.

Findings

Owing to line balancing, the cycle time of cylinder block line was reduced from 293.9 to 200 s, an almost 32 per cent reduction. This also resulted in increased throughput and machine utilisation. Throughput was increased by 65 per cent. Machine utilization was found to increase at all stations, with the highest increase at one station was recorded from 48 to 95 per cent due to balancing.

Originality/value

Introduces a new application to line balancing of automotive cylinder block production line. Demonstrates that effective strategies of re‐sequencing and changing of tools can lead to more balanced production line with increased throughput and higher machining utilisation, resulting in higher productivity.

Details

Assembly Automation, vol. 26 no. 1
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 1 January 1993

Mario Tabucanon and Wang Changli

Outlines the specific characteristics of semiautomatic productionlines which, in relative terms, are given less attention than othertypes of line. Suggests a methodology for…

Abstract

Outlines the specific characteristics of semiautomatic production lines which, in relative terms, are given less attention than other types of line. Suggests a methodology for balancing such lines, making comparison thereof with the traditional method of line balancing. Applies the method to a case which is a typical semiautomatic line.

Details

Integrated Manufacturing Systems, vol. 4 no. 1
Type: Research Article
ISSN: 0957-6061

Keywords

Article
Publication date: 22 December 2021

Weilei Shen, Qiangqiang Jiang and Yang Yang

The purpose of this paper is to construct a task assignment model for U-shaped production lines with collaborative task, which is optimized by minimizing the number of workers and…

Abstract

Purpose

The purpose of this paper is to construct a task assignment model for U-shaped production lines with collaborative task, which is optimized by minimizing the number of workers and balancing the workload of the operators. The ultimate goal is to increase productivity by increasing the U-line balance and balancing the load on the operators.

Design/methodology/approach

First, task selection and update mechanism are analyzed and the task selection mechanism suitable for collaborative task is proposed. Second, M-COMOSAL is obtained by improving the original COMOSAL. Finally, The M-COMOSAL algorithm and the COMAOSAL algorithm are used to perform job assignment on the double-acting clutch U-shaped assembly line.

Findings

According to the allocation scheme obtained by M-COMSOAL, the beat can be adjusted according to the change of order demand. The final allocation scheme is superior to the COMSOAL algorithm in terms of number of workers, working time, production tempo and balance rate. In particular, compared with the old scheme, the new scheme showed a decrease of 16.7% in the number of employees and a 18.8% increase in the production line balance rate. Thus, the method is helpful to reduce the number of operators and balance the workload.

Originality/value

The new algorithm proposed in this paper for the assignment of collaborative task can minimize the number of workers and balance the load of operators, which is of great significance for improving the balance rate of U-shaped production lines and the utilization of personnel or equipment.

Details

Assembly Automation, vol. 42 no. 1
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 1 June 1987

T.K. Bhattacharjee and S. Sahu

This paper briefly reviews the assembly line balancing techniques developed over the last 30 years. It attempts to establish the direction of research, to identify unexplored…

Abstract

This paper briefly reviews the assembly line balancing techniques developed over the last 30 years. It attempts to establish the direction of research, to identify unexplored areas with potential for study and recommends future courses of action.

Details

International Journal of Operations & Production Management, vol. 7 no. 6
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 27 September 2011

Tom McNamara, Sabry Shaaban and Sarah Hudson

The purpose of this paper is to investigate the performance of unpaced reliable production lines that are unbalanced in terms of their mean operation times, coefficients of…

Abstract

Purpose

The purpose of this paper is to investigate the performance of unpaced reliable production lines that are unbalanced in terms of their mean operation times, coefficients of variation and buffer capacities.

Design/methodology/approach

Simulations were carried out for five‐ and eight‐station lines with various buffer capacities and degrees of means imbalance. Throughput, idle time and average buffer level performance indicators were generated and statistically analysed.

Findings

The results show that an inverted bowl allocation of mean service times, combined with a bowl configuration for coefficients of variation and a decreasing order of buffer sizes results in higher throughput and lower idle times than a balanced line counterpart. In addition, considerable reductions in average inventory levels were consistently obtained when utilizing a configuration of progressively faster stations, coupled with a bowl‐shaped pattern for coefficients of variation and an ascending buffer size order.

Research limitations/implications

The results for these specific experiments imply that resources expended on trying to achieve a balanced line could be better used by seizing upon possible enhanced performance via controlled mean time, variability and buffer imbalance. Results are valid for only the line type and parameter values used (simulation results are specific and not general).

Practical implications

Guidelines are provided on design strategies for allocating labour and capital unevenly in unpaced lines for better performance in terms of increased throughput or lowered idle time or average buffer levels.

Originality/value

This paper might be viewed as one of the first simulation investigations into the performance of unpaced production lines with three sources of imbalance.

Article
Publication date: 16 February 2022

Bao Chao, Chaoyong Zhang, Yu Zhang, Hongfei Guo, Yaping Ren and Hao Zhang

This paper aims to provide feasible countermeasures for the application of lean manufacturing in automatic sand casting workshops to optimize production line balance.

Abstract

Purpose

This paper aims to provide feasible countermeasures for the application of lean manufacturing in automatic sand casting workshops to optimize production line balance.

Design/methodology/approach

A production line balance optimization model for sand casting workshops is proposed. The value stream mapping (VSM) approach is applied to diagnose the problems in the production process. An optimization scheme is established based on eliminate, combine, rearrange, simplify and increase theory and Kanban management method. Further, simulation is done to compare current VSM and future VSM.

Findings

After implementing the proposed model, findings indicated that the idle time of equipment was effectively reduced, the line of balance of the production line was increased by 44.7%, the production lead time was shortened by 60.3% and the production capacity was increased by 50.0%.

Research limitations/implications

Application of the optimization model in this study is limited to sand casting workshops that have realized automatic or semi-automatic production.

Originality/value

This paper provides an optimization model for the implementation of lean manufacturing in sand casting workshops and provides a reference case that reflects the actual application of lean manufacturing tools in a real situation.

Details

International Journal of Lean Six Sigma, vol. 13 no. 6
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 4 November 2019

Shuqiang Wang, Jia Tang, Yiquan Zou and Qihui Zhou

The purpose of this paper is to investigate the process optimization of a precast concrete component production line by using value stream mapping.

1596

Abstract

Purpose

The purpose of this paper is to investigate the process optimization of a precast concrete component production line by using value stream mapping.

Design/methodology/approach

This paper is an empirical focused on of lean production theory and value stream mapping. The data in the case study were collected in real time on-site for each process during the production process of a prefabricated exterior wall.

Findings

The results of the current value stream map indicate that the main problems of the current production process are related to equipment, technology and organization. The equipment problems include simple demolding and cleaning tools and the lack of professional transfer channels. The technology problems include the lack of a marking mechanism and pipeline exit mechanism. There is a lack of standard operating procedures and incomplete process convergence. A comparison and analysis of the current value stream and the future value flow indicate that optimizations of the process flow, the production line layout, and the standard operating procedures have shortened the delivery cycle, reduced the number of workers, improved the operator’s operating level and balanced the production line.

Practical implications

The results of this study provide practitioners with a clear understanding of the optimization of the precast concrete component production and represent a method and basis for the process optimization of a factory production line; the approach is suitable for process optimization in other areas.

Originality/value

This research represents an innovative application of lean production theory and value stream mapping in a complex production line of precast concrete components and thereby fills the gap between the theory and practice of the optimization of a precast concrete component production line.

Details

Engineering, Construction and Architectural Management, vol. 27 no. 4
Type: Research Article
ISSN: 0969-9988

Keywords

Article
Publication date: 1 December 2001

Sung‐Yong Son, Tava Lennon Olsen and Derek Yip‐Hoi

Line balancing has been an important technique for manufacturing system design, because a completely balanced system can provide maximum resource utilization at the designed…

1589

Abstract

Line balancing has been an important technique for manufacturing system design, because a completely balanced system can provide maximum resource utilization at the designed capacity. However, even if a system is completely balanced, it still has capacity waste when the entire product life cycle is considered, because real production is often significantly less than capacity. Avoiding this mismatch requires scalable systems such as reconfigurable manufacturing systems (RMSs) to meet changing product demand. Stage paralleling is suggested as an approach to scalability for RMSs. By comparing the economic feasibility of such manufacturing systems with completely balanced transfer line systems with respect to station cost, it is shown that line balancing is not necessarily desirable with this approach. The effect of station cost differences for unbalanced systems is also considered.

Details

Integrated Manufacturing Systems, vol. 12 no. 7
Type: Research Article
ISSN: 0957-6061

Keywords

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