Description
Research Assignment #2 Literature Critique
Write a two-page literature critique on the individually assigned IE topic shown in the table below. You must use TWO peer-reviewed refereed journal articles for this assignment where each page should be a summary of each article.
My topic is Electronic Assembly.
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Explanation & Answer
Please go through the answer and let me know if everything is in order. Kindly rate me if the answer is okay. Thanks.
Here are the articles that I used.
International Journal of Current Engineering and Technology
E-ISSN 2277 – 4106, P-ISSN 2347 - 5161
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©2014 INPRESSCO , All Rights Reserved
Available at http://inpressco.com/category/ijcet
Case Study
Assembly line Balancing: A Case Study in Silencer Manufacturing
Shriram SaneȦ, Varsha KarandikarȦ*, Rahul PulkurteȦ and Subodh PatilȦ
Ȧ
Industrial and Production Engineering Department, Vishwakarma Institute of Technology, University of Pune, Pune, Maharashtra, India
Accepted 02 May 2014, Available online 01 June 2014, Vol.4, No.3 (June 2014)
Abstract
An assembly line balancing is to know how tasks are to be assigned to workstations, so that the predetermined goal is
achieved. Minimization of the number of workstations and maximization of the production rate are the most common
goals. The silencer assembly line is studied in this paper which assembles four products. For line improvement purpose,
various Lean Manufacturing tools are employed such as cycle time study, line imbalance calculation, bottleneck
identification, Kaizen, space utilization through layout change. Many industries are facing lot of problems like inability
to meet production targets, imbalance of work content at work stations, discontinuity in material flow, manpower
allotment. In this paper, the design to evaluate the performance, bottleneck identification , reduction in bottleneck
cycle time, minimizing line imbalance, workstations organization, reduction in manpower and space saving,
increasing manpower utilization of industrial production assembly line are discussed.
Keywords: Assembly Line Balancing, Cycle Time Reduction, resource utilization
1. Introduction
1
Line Balancing means balancing the production line, or
any assembly line. The main objective of line balancing is
to distribute the task evenly over the work station so that
idle time of man of machine can be minimized by Naveen
Kumar and Dalgobind Mahto (2013). Varsha Narayan
Karandikar, Shriram Madhukar Sane (2014), discussed
waste identification and elimination and de-bottlenecking
to balance the line and optimize utilization of resources for
improving the productivity. Cycle time reduction is one
of the most important elements of successful
manufacturing today, Assembly line balancing is the
process of distributing work load in an assembly line
across successive workstations so that no resource and
time
are
wasted is studied by Meby Mathew,
D.Samuelraj (2013). Takt time is the rate at which
products or services should be produced to meet the
customer demand. Bottleneck Delay in transmission that
slow down the production rate this can be overcome by
balancing the line. Naveen Kumar & Dalgobind Mahto
(2013) in their paper the improvement in knowledge, the
refinement in the application of line balancing procedure
is also a must. Task allocation of each worker was
achieved by assembly line balancing to increase an
assembly efficiency and effective use of manpower
.Varsha Narayan Karandikar, Shriram Madhukar Sane
(2013) described the newly defined Posture – State
Variation Report [P-SVR] method of postural analysis to
highlight the areas for improvement in work posture for
*Corresponding author Varsha Karandikar is working as Assistant
Professor; Shriram Sane as Professor and Rahul Pulkurte and Subodh
Patil are students
operator comfort and to find out quantitative value of
severity of work based upon postural video analysis.
Varsha Karandikar, S. M. Sane (2013), investigated the
investigated the ergonomics aspect of machine design of
work station to kill the root cause of the problem. And
also explained the procedure for determining the
workstation dimensions and layout has been explained.
1.1 Formulae
%
Efficiency =
Takt time=
2. Methodology
2.1 Cycle Time Study
First of all, to know the production capability of each
individual station, detailed cycle time study at each
workstation is carried out. Cycle time study is done for 5
repetitive cycles. Then, activities are sorted in VA(Value
added)/NNVA(Non
Value
added
activity)/PNVA
(Partially non value added activity) activities. NNVA
activities are focused to eliminate or reduce and NVA
activities are focused to eliminate.
2.2 Current State of the Line
In this all the workstation time study is carried out 7
wastes (TIMWOOD) are identified at each workstation.
Also, Line imbalance ratio is also calculated. At initial
1583 | International Journal of Current Engineering and Technology, Vol.4, No.3 (June 2014)
Shriram Sane et al
Assembly line Balancing: A Case Study in Silencer Manufacturing
Inner & Outer Pipe Welding
Shot Filling
CNC Bending
Shot Removal
Machine Steel Shot filling
Gauge Inspection
Leakage Testing
CO2 Welding
Drilling
Cover tube Welding
Leakage Testing
Peicring
Sizzing Machine
Inspection
45
40
35
30
25
20
15
10
5
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
NVA
VA
Takt Time
Figure 1: Initial State of line Balancing
level, line imbalance percentage for the line (Pipe B) is
46.04%. Number of operators employed on the line is 14.
2.3 Initial State of the Line
Following figure shows graphical representation of the
cycle time of workstation along with TAKT time and
Target rate. Workstations having total cycle time more
than the target are bottleneck station which should be
considered for the improvement on priority.
Table 1: State Of Line before Line Balancing (With 14
Operators)
The flow of material is not continuous as shown in the
Layout figure 5(Before). And Manpower workload is very
less as shown in figure 1. The Manpower required for
these two stations are two. When these workstations are
clubbed the distance is minimized between these two
workstations and it helped to deploy single manpower for
both workstations. This change doesn’t affect the
production rate before and after the Improvement as the
Takt time for each workstation is 37.7 sec. By clubbing
these two workstations cycle time=17.62 sec. which is less
than the required takt time.
3.3 Cover Tube Round Welding
3. Bottleneck identification and elimination
In this cover tube welding operation the operator needs to
pick up the pipe, cover tube and welding is carried out. At
this workstation the cover tubes are placed on the welding
machine, not more than 20 pieces are placed. After
completing 20 jobs he needs to go storage and bring the
cover tube simultaneously. The operator needs to bring
material from storage 5 times in hour. To re...