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1 – 10 of over 52000Assembly 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.
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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…
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.
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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…
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.
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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.
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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.
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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.
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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.
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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.
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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.
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.
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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…
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.
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