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Under Guidance Of Prof. S. S. Aphale

KJ’s Trinity Academy Of Engineering , Pune

A Project On

“DEPLOYMENT OF MANUFACTURING FLEXIBILTY”

Presented By: 1 Mr. M.B. Kadam (38) 2 Mr. A.B. Mhaske (56) 3 Mr. S.R. Jadhav (31)

4 Mr. R.P. Karpe (41)

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Literature Review Shriram Sane et al [1] have analyzed Assembly line Balancing: A Case Study

in Silencer Manufacturing. An assembly line balancing is to know how tasks are to be assigned to workstations, so that the predetermined goal is achieved.

S. Santosh kumar et al [2] has studied Cycle time reduction of a truck body assembly in an automobile industry by lean manufacturing.

R.B. Breginski et al [3] have analyzed ASSEMBLY LINE BALANCING USING EIGHT HEURISTICS.

Lamia A. Shihata [4] studied Two-sided assembly line balancing of refrigeration assembly lines. The application of lean manufacturing on pre-assembly and final assembly activities lines is attempted.

S. Sathish et al [5] studied Assembly Line Efficiency Measurement and Line Balancing-A Case Study on Automobile Cluster Assembly Line.

Lim Chuan Pei et al [6] have analyzed IMPROVING PRODUCTIVITY THROUGH LINE BALANCING - A CASE STUDY. This paper describes a case study conducted at a manufacturing company aimed at improving productivity using line balancing.

Artun Torenli [7] has studied Assembly line design and optimization

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INTRODUCTION

Assembly line balancing is the process of distributing the work load in an assembly line across workstation, so that no resources and time is wasted.

To Balance the vehicle assembly line, cycle time is the most important element.

Hence cycle time reduction is one of the most important elements of successful manufacturing today.

To complete the customer demands with deliver perfect quality product on time, the manufacturer has to focus more attention on cycle time.

According to demand the takt time and cycle time must be equal.

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Our Project Work is focused on assembly line for the reduction of cycle time in the assembly of newly launched ‘TATA Winger (ABS Version).

The planned production in one shift is 31 but the actual production is only near about 25-26 vehicles. The total productive time in one shift is 455 min.

The total no. of stations are 31. Operating time varies from 1 min. to 40 minute, due to

this many stations wait for the other stations to complete the operations.

The time taken by each operator is different in the same station and the work load of each operator different .

Problem Definition

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Bottleneck identification and elimination To balance assembly line To study the ABS Winger Compare the result with the existing assembly line

2. Objective

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    STD. Time

FINAL TIME

Opr no Operations Operators

  VC NO-28451035ABFR STW ABS                    

  TRIM STATION 00 ST00-1 ST00-2 ST00-3 ST00-4 ST00-5 ST00-6 ST00-7 ST00-8 ST00-9  

1Audit for Paint Damages 2.35                  2.35

2Fitment of Top Rail channel Beading with Clip   2.91 2.91              5.82

3Fitment of Drip rail       1.99            1.99

4Fitment of moscot and rub rail         7.37 7.37        14.74

5Black and red sticker pasting   0.545  0.545            1.09

6Dropping Cab On Main Conveyor             1.92      1.92

7Dropping on conveyer stand             1      1

8Fitment Of Protective Cover On Cab             1.09      1.09

9Removal Of Bottom Cups             1.63      1.63

10Condensor fitment(Stretch winger)               19.57 19.57  39.14

  TOTAL 2.35 3.45 2.91 2.53 7.37 7.37 5.64 19.57 19.57  70.77

                         

  TRIM STATION 01 ST01-1 ST01-2 ST01-3 ST01-4 ST01-5 ST01-6 ST01-7 ST01-8      

1Fitment of Wiring harness Tail door RH, Front Doors LH/RH & Roof cables 1.17 1.17                2.35

2Fitment of Stay rod and clamp with sleeve     1.63              1.63

3Fitment of all Grommets and Insulation     3.14 3.14            6.29

4Fitment of magnet and stopper         1.63 1.63        3.27

5Fitment of Rear shackle LH/RH             0.9 0.9    1.81

6Fitment of Rear Shock Absorber LH/RH with cover             2.54 2.54    5.09

7Fitment of Mc Pherson Strut with cover LH/RH, Wheel arch insulation front             2.6 2.6    5.2

  TOTAL 1.17 1.17 4.77 3.14 1.63 1.63 6.04 6.04    25.64

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  TRIM STATION 03 ST03-1 ST03-2 ST03-3 ST03-4 ST03-5 ST03-6 ST03-7        

1Bar code printing / pasting 1.99                  1.99

2Fitment of windshield washing unit with hose and nozzle   2.9                2.9

3Fitment of fresh air unit inside dashboard for ac dashboard mounting bracket         3.36 3.36        6.72

4Fit of Cabin cable & ECU connection switch insulation         0.81 0.81        1.63

5Fitment of Energy absorber LH/RH rear and Front and side             4.64      4.64

6Fitment of wiper motor     3.23              3.23

7 Fitment Engine lamp       1.31            1.31

  TOTAL 1.99 2.9 3.23 1.31 4.17 4.17 4.64      22.42

                         

  TRIM STATION 04 ST04-1 ST04-2 ST04-3 ST04-4 ST04-5 ST03-2 ST03-3        

1Fitment of auxiliary tank with hoses           1.99        1.99

2Fitment of fresh air unit in Engine house             3.09      3.09

3Fitment of side repeater lamps and Tail Lamp 8.55                  8.55

4Fitment of front door check strap   5.63                5.63

5Fitment of Control Mtg.     1.19 1.19            2.38

6Fitment of Strg.colmn with upper bkt.     2.31 2.31            4.63

7Fitment of Parking brake     0.9 0.9            1.81

8Fitment of rear center bumper         7.27          7.27

  TOTAL 8.55 5.63 4.4 4.4 7.27 1.99 3.09      35.35

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  TRIM STATION 05 ST05-1 ST05-2 ST03-2 ST03-3 ST03-4            

1Fitment of horn mounting bracket and horn Fitment     1.81              1.81

2Air filter assy and suction pipe       6.81            6.81

3Fitment of PS Bottle with Hose         1.94          1.94

4Fitment of Fuel Neck and acc.pedal 1.63 1.63                3.27

5Fitment of Front mat with Engine hood 3.08                  3.08

6fitment of battery tray   12.92                12.92

  TOTAL 4.71 14.55 1.81 6.81 1.94          29.83

                         

  TRIM STATION 06 ST06-1 ST06-2 ST06-3 ST06-4 ST06-5 ST06-6 ST06-7 ST06-8 ST06-9 ST04-3  

1Fitment of roof AC unit 1.34 1.34                2.68

2Fitment of booster cable with routing                   5.4 5.4

3Fitment of Brake pipes in engine house     1.94              1.94

4Insertion of clutch cable with clamps     3.49 3.49            6.99

5Fitment of acc. cable       2.56            2.56

6Fit of rear door cladding LHS/RHS         4.64          4.64

7Fitment of inner latch control unit , striker and outer handle for LHS/RHS front door           5.46        5.46

8Fitment of window winding LHS/RHS             5.63      5.63

9Fitment of rear door latch control unit with links and outer handle               2.73    2.73

10Fitment of Roof lamp, Sunvisor roof handles               2.38    2.38

11Fitment of dome and triangular plate                 3.55  3.55

  TOTAL 1.34 1.34 5.43 6.05 4.64 5.46 5.63 5.11 3.55 5.4 43.96

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  TRIM STATION 07STO7-1 ST07-2 ST07-3 ST07-4 ST07-5 ST07-6 ST07-7        

1Fitment of inner seat belt 1.99                  1.99

2Fitment of B pillar AC pipes with connection   14.01                14.01

3Fitment of rear door top and bottom strikers body side     6.36              6.36

4Fitment of all beadings body side Front door       8.35            8.35

5Fitment of Door switch and connect to Door cable         2.19          2.19

6Fitment of Heater Connection           3.05        3.05

7Fitment of dashboard +control unit         7.92 7.92        15.84

8Fitment of of triangular glass with glass guide channel beading             4.29      4.29

  TOTAL 1.99 14.01 6.36 8.35 10.11 10.97 4.29      56.08

                         

  TRIM STATION 08 ST08-1 ST08-2 ST08-3 ST08-4              

1Fitment of all beadings body side Rear door 7.69                  7.69

2Fitment of ignition (main line ) switch     1.94              1.94

3Fitment of combi switch     0.81 0.81            1.63

4Fitment of nacelle       0.9            0.9

5Door glass assy+ Fitment of front door glass assy   1.52                1.52

  TOTAL 7.69 1.52 2.75 1.71            13.68

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  TRIM STATION 09 ST09-1 ST09-2 ST09-3 ST09-4              

1Fitment of foot step 4.16                  4.16

2Fitment of head lamps LH/RH with protective cover   1.39 1.39              2.79

3Fitment of intercooler with Mud Liner   4.74 4.74              9.48

4Fitment of division bar with velvet channel +H grommet       6.28            6.28

5Front door glass setting       4.74            4.74

  TOTAL 4.16 6.13 6.13 11.02            27.45

                         

  TRIM STATION 10 ST10-1 ST10-2                  

1Fitment of plastic membrane front door inner side with all grommets 2.29 2.29                4.58

2Fitment of front door Pad magazine For Sardina Red – fit speaker Grill 3 3                6

3Fitment of window winding handle 0.42 0.42                0.85

4Fitment of Weather strip 0.49 0.49                0.99

  TOTAL 6.2 6.2                12.42

                         

  TRIM STATION 11 ST11-1 ST11-2 ST11-3 ST11-4 ST11-5 ST11-6 ST11-7 ST11-8 ST11-9    

1Fitment of headlamp LH/RH 0.93 0.93                1.86

2Fitment of leaf screen and wiper blade 1.05 1.05                2.1

3Fitment of GPT and Flasher 0.9 0.9                1.81

4Fitment of bonnet plastic cover 0.72 0.72                1.45

5Fitment of sliding window LH/RH     1.16 1.16 1.16 1.16        4.64

6Fitment of Transfer Labels             0.68      0.68

7Fitment of cluster and cluster cover             4.91      4.91

8Fitment of plastic membrane rear door and all plastic grommets               1.6 1.6  3.2

9Fitment of rear door pad and Check Strap               2.81 2.81  5.63  TOTAL 3.6 3.6 1.16 1.16 1.16 1.16 5.59 4.41 4.41  26.28

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  TRIM STATION 12 ST12-1 ST12-2 ST12-3 ST12-4 ST12-5 ST12-6          

1Fitment of rear door glasses and rear door outer beadings 7.64                  7.64

2Sub-assembly and fitment of Windshield glass   0.96 0.96 0.96            2.9

3Pasting of RFID sticker on Windshield glass     0.72              0.72

4Fitment of Inner IRVM       1.63            1.63

5Fitment of front AC         7.92 7.92        15.84

6Fitment of front ac trim with louvers         4.24 4.24        8.49

7Fitment of front ac Outlet evaporator end         0.27 0.27        0.54

8Fitment of front ac inlet evaporator end         0.98 0.98        1.97

  TOTAL 7.64 0.96 1.68 2.59 13.41 13.41        39.73

                         

  TRIM STATION 13 ST13-1 ST13-2 ST13-3 ST13-4              

1Fitment of wiper blade and setting 2.28                  2.28

2Tail door gap and flushness   2.73                2.73

3Front door gap and flushness     3.27              3.27

4Fitment of all seat belt       6.11            6.11

  TOTAL 2.28 2.73 3.27 6.11            14.39

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  TRIM STATION 14 ST14-1 ST14-2 ST14-3 ST14-4 ST14-5            

1Connection of clutch cable to pedal with fixture 2.9                  2.9

2Fitment of A pillar handle   1.5                1.5

3Front door latch & strikar torquing     1.45              1.45

4Oiling of all hinges and check strap   1.92                1.92

5Quality inspection Gate for Fitment station 0 to 14 and Rectification       5.26 5.26          10.52

  TOTAL 2.9 3.42 1.45 5.26 5.26          18.29

                         

  TRIM STATION 15                      

1Lifting of trim cab                     33.83

                         

  UB STATION NO 1 UB1-1 UB1-2 UB1-3 UB1-4 UB1-5 UB1-6 UB1-7        

1Fitment of all grommets(fuel tank, release lever, brake pipe, fuel pipe) 1.63                  1.63

2Fitment of Fuel Tank and Hose connection   2.49 2.49 2.49            7.47

3Fitment of brake pipe line routing and clamping on long cross member         4.91          4.91

4Fitment of AC Pipe           1.81        1.81

5Fitment of bump stopper to cab             2.45      2.45

6Fitment of Rear Anti Roll Bar mounting bracket on Cab 2.9                  2.9

7Fitment of Vacuum Tank bracket & Vacuum tank           6.82        6.82

8Hose assembly liquid pipe joint to main condenser           2.08        2.08

9Assembly roof AC liquid pipe to receiver outlet pipe           2.87        2.87

  TOTAL 4.53 2.49 2.49 2.49 4.91 13.58 2.45      32.94

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  UB STATION NO 2 UB2-1 UB2-2 UB2-3                

1Fitment of clutch cable connection 2.35                  2.35

2Fitment of Front Sub Frame with Cab after Engine Stuffing 5.09                  5.09

3Fitment of Rear Sub Frame with Cab after Engine stuffing   3.99                3.99

4Fitment of Tie member   1.17                1.17

5Fitment of Front Antiroll Bar (Mounting bracket bolt tightening with sub frame and cab - LH/RH)     3              3

6Fitment of Gear Box Mounting Block   0.99                0.99

7front to rear break pipe fitment routing and clamping 4.18                  4.18

8fitment of ABS ECU W/H and routing     1.81              1.81

  TOTAL 11.62 6.15 4.81              22.58

                        

  ENGINE SUBASSEMBLY ES1 ES2 ES3 ES4 ES5 ES6 ES7        

1Fitment of Rack & Pinion to front sub frame 1.85                  1.85

2Fitment of Power steering Hose connection to pump (Banjo bolt with copper washer)   0.9                0.9

3Fitment of Power steering Hose connection to Rack & Pinion 1.47                  1.47

4Fitment of Gear Box to hinged bracket ( 3rd Mounting )     0.99              0.99

5Fitment of Gear Box to Gear Box mounting block     1.09              1.09

6Fitment of Engine mounting Pad       1.26            1.26

7Fitment of Engine mounting Arm (Pad side flange)       2.02            2.02

8fitment of assy ABS modulator and bkt with break pipe on sub frame   4.91  4.95            9.83

9fitment of W/H to engine         0.81          0.81

10fitment of drive shaft           1.81        1.81

11Hose connection intercooler to engine cylinder inlet         5.27          5.27

12Lifting of engine             0.95      0.95

13fitment of insulation with clip on silencer             3.27      3.27

14fitment of heater connection           1.27        1.27

  TOTAL 3.32 5.81 2.08 8.23 6.08 3.08 4.22      32.86

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  UB STATION NO 3 UB3-1 UB3-2 UB3-3 UB3-4 UB3-5            

1Fitment of Steering Column U-Joint Connection & its cover 0.54                  0.54

2Fitment of Stub axle LH/RH with strut   1.13 1.13              2.27

3Fitment of Ball Joint of Stub axle into lower wishbone       2.63            2.63

4Fitment of ball joint of Rack and Pinion into stub axle     3.55              3.55

5fitment front sensor cable with bkt   1.09 1.09              2.18

6Fitment of brake pipes to caliper flexible hose 0.72                  0.72

7W/H connection to front WSS     0.72              0.72

8Fitment of 2nd alternator connection         4.91          4.91

  TOTAL 1.26 2.22 6.49 2.63 4.91          17.54

                        

  UB STATION NO 4 UB4-1 UB4-2 UB4-3 UB4-4              

1AC pipe assembly roof AC pipe to Compressor suction pipes joints 0.76 0.76                1.52

2Fitment of silencer with steel end 1.17                  1.17

3Hanging of silencer to cab with rubber grommets 2.41 2.41                4.82

4Fitment of silencer assembly     2.82 2.82            5.65

5Fit of Rear shackle support bracket to cab LH/RH   1.81                1.81

  TOTAL 4.34 4.98 2.82 2.82            15.01

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  UB STATION NO 5                      

  UB STATION NO 6 UB6-1 UB6-2 UB6-3 UB6-4 UB6-5 UB6-6 UB6-7 UB6-8      

1Fitment of Rear Axle assembly using lifting table 5.89                  5.89

2Fitment of leaf spring at Front Fixed end 2.26                  2.26

3Fitment of U-bolts   2.53                2.53

4Fitment of leaf spring at Rear Shackle End (Top & bottom)     1.3              1.3

5fitment of Rear Shock Absorber at Axle beam       1.31            1.31

6Fitment of Rear Anti Roll bar     2.55 2.55            5.11

7Fitment of engine earthing cable to cab         0.9          0.9

8Fitment of parking brake system assembly           4.73        4.73

9Fitment of AC pipe-Assembly main condenser to C pipe joint         0.9          0.9

10Fitment of AC pipe-Assembly main condenser to Auxiliary condenser pipe joint         3.36          3.36

11Fitment of AC pipe-Solenoid pipes joints         0.63          0.63

12Fitment of T-connector with brake pipes on axle beam     4.18              4.18

13Fitment of fuel neck hose             0.44      0.44

14Fitment of intercooler bottom hose               1.73    1.73

15Fitment of all wheels     2.22        2.22    4.45

16fitment of rear sensor cable with bkt 2.29                  2.29

17W/H connection to rear WSS         0.9          0.9

  TOTAL 10.44 2.53 10.25 3.86 6.69 4.73 0.44 3.95    42.98

                         

  MECHANICAL LINE                      

  MECH STATION NO 1 M1-1 M1-2                  

1Fitment of Driver seat 6.58                  6.58

2Fitment of Co-driver’s seat 6.68                  6.68

3Fitment of Steering Wheel 0.71                  0.71

4Fitment of battery with clamp   10.79                10.79

  TOTAL 13.97 10.79                24.77

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  MECH STATION NO 2 M2-1 M2-2 M2-3 M2-4 M2-5            

1Fitment of fuel filter and fuel pipe inlet & return connection 3.94 3.94                7.89

2Fitment of radiator     2.38              2.38

3Fitment of radiator hose connection & Fitment of auxiliary hose connection       2.23 2.23          4.46

4Fitment of AC main condenser     2.64              2.64

5Diesel filling from the tank and Priming 1                  1

6Fitment of AC pipe compressor to condenser   1.78                1.78

7Fitment of AC pipe joint hose assembly suction A to assembly pipe outlet evaporator       1.07            1.07

8Inter cooler Hose connection   1.07                1.07

9Air filter hose connection + Air filter sensor connection       1.61 1.61          3.23

10Fitment of AC pipe- Pipe assembly A receiver outlet to pipe assembly inlet evaporator 2.42                  2.42

  TOTAL 7.36 6.79 5.02 4.91 3.84          27.98

                        

  MECH STATION NO 3 M3-1 M4-1 M4-3                

1Fitment of Battery with Clamp 5.47                  5.47

2Electrical Connections Testing 2.26                  2.26

3Fitment of Battery connections with applying Jelly 3.05                  3.05

4Brake oil filling   6.19                6.19

5CV Shaft nut torquing and knotching     1.16              1.16

  TOTAL 10.78 6.19 1.16              18.15

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  MECH STATION NO 4 & 5 M4-1 M4-2 M4-3 M4-4              

1Filling of Radiator Coolant 5.02                  5.02

2AC Gas Filling 9.16                  9.16

3Power steering Hydraulic oil filling & Bleeding   4.58                4.58

4Fitment of Center grill with Indicators   1.88                1.88

5Fitment of Front Bumper with Fog Lamp   5.74                5.74

6Accelerator pedal setting     3.23              3.23

7Fitment of all stickers     1.25              1.25

8Fitment of Gear lever knob & Bellow     1.61              1.61

9Fitment of Decals and reflectors       2.96            2.96

  TOTAL 14.18 12.2 6.09 2.96            35.46

                        

  MECH STATION NO 6                      

  GATE 02 G1                    

1Quality Inspection Gate (G5 ) for Fitment station 1 to 5 5.33                  5.33

  TOTAL 5.33                  5.33

                        

  UNDER PIT 1 UP1 UP2 UP3 UP4 UP5            

1Tightening of lower wishbone pin 1.61                  1.61

2Fitment of Toe-in check nut   1.16                1.16

3Brake Switch Setting   1.07                1.07

4Steering Geometry Check     1.61 1.61 1.61          4.85

5Brake checking and Bleeding   1.7                1.7

  TOTAL 1.61 3.93 1.61 1.61 1.61          10.41

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  DRIVE TEST D1                    

1Torquing to steering wheel ( After spoke alignment) 1.16                  1.16

2Roll braking test 7.49                  7.49

  TOTAL 8.65                  8.65

                        

  UNDERPIT-2 UP2-1 UP2-2 UP2-3 UP2-4              

1Wiper jet setting     3.4              3.4

2Wheel cap fitment     1.18              1.18

3FICD fitment     0.17              0.17

4Bottom shield fitment     1.07              1.07

5Smoke test 2.15  2.15              4.31

6Side foot fitment   3.94                3.94

7Torquing & Notching of lower wishbone pin       2.86            2.86

8Handbrake notch setting       2.15            2.15

9Clutch reverse play setting 2.15                  2.15

  TOTAL 4.3 3.94 7.97 5.01            20.68

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  PDI PDI-1 PDI-2 PDI-3 PDI-4 PDI-5            

1Adjust head lamp flushness & gaps 4.72                  4.72

2Check for leakags   4.85                4.85

3Bumper gap setting 1.59                  1.59

4Bonnet setting ( Gap & flushness ) 8.89                  8.89

5Bonnet to grill gap 3.82                  3.82

6Tail door gap & flushness setting     10.02              10.02

7fitment of rear foot step       4.31            4.31

8Cross Cheking         6.46          6.46

9Chassis number punching     2.19 2.19            4.39

10fitment of ORVM       3.23            3.23

11Rear Side bumper   3.23                3.23

  TOTAL 19.02 8.08 12.21 9.73 6.46          55.56

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Bottleneck identification and elimination

10

5

10

15

20

25

19.57

6.05

4.69

4.64

8.55

14.55

6.06

14.01

7.69

11.02

6.22

5.59

13.42

6.115.26

13.58

11.62

8.2

6.54.98

10.44

13.97

7.37

10.78

14.18

5.333.93

8.787.48

19.02

CYCLE TIME VS TAKT TIME

STATION NO

TIME

00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 U1 U2 EA U3 U4 U5 M1 M2 M3 M4 M5 UP1 D UP2 PDI

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Current Assembly line observation

Required production (Demand) = 31 vehicle per shiftTotal time available = 455 minute per shiftTakt time =14.67 minuteTotal operation time =865.22 minuteTotal cycle time =279.91 minuteMaximum Cycle time = 19.57 minuteTotal no of operation =221Total no of operator = 153 Total production by cycle time = 24 units

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Calculations Line balancing efficiency

Labor productivity

Line balancing loss

η = 28.89%

Labor productivity = 15.68 %

η = 53.85 %

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Fitment of roof condenser

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Assembly line balancing

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Line Balancing and Resource Optimization Summarized

10

2

4

6

8

10

12

14

16

7.79

6.04

9.88

7.44

10.71

12.92 12.8

14.01

7.69

11.02

6.22

7.54

13.42

8.39

5.26

11.5 11.62

8.2

6.5

4.98

10.44

13.97

7.37

10.78

14.18

5.33

5.54

8.78

7.48

14.3

CYCLE TIME VS TAKT TIME

STATION NO

TIME

00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 U1 U2 EA U3 U4 U5 M1 M2 M3 M4 M5 UP1 D UP2 PDI

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Takt time =14.67 minuteTotal operation time =865.22 minuteTotal cycle time =268.28 minuteMaximum Cycle time = 14.30 minuteTotal no of operation = 221Total no of operator = 124Total production by cycle time = 31 units

Observation After line balancing

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Calculations Line balancing efficiency

Labor productivity

Line balancing loss

η = 48.89%

Labor productivity = 25 %

η = 39.50 %

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Sr. no. Content Before After

1 Takt time 14.67 min 14.67 min

2 Total operation time 865.22 min. 865.22 min.

3 Total cycle time 279.91 min. 268.23 min.

4 maximum cycle time 19.57 min. 14.3 min.

5Total number of operator 153 124

6Total production by cycle time 24 31

7Line balancing efficiency 28.89 % 48.79 %

8 Labor productivity 15.68 % 25 %

9 Line Balancing Loss 53.85 % 39.5 %

Result:-

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Hence ,according to time-study total no. of operators are 153 & bottleneck operations found through time study are : 1) Roof condenser Fitment & 2) Pre-dispatch Inspection .

As focus of Project is the elimination of bottleneck operation “ Roof -condenser fitment “

So the Proposed layout for this fitment is much beneficial than current layout. The time req. for one fitment according the current layout is 19.39min. But according to the New Proposed layout , the time req. get reduced to 6.39

min. only. Thus, the one of the major bottleneck operations gets eliminated. Also, after Re-distributing the task amongst operators ,the no of operators gets

reduced to 124. Also the line balancing loss, also reduced to 39.5% from 53.85% . Labour productivity is also increased to 25% from 15.68%. Line balancing efficiency also increased to 48.79% from 28.89%.

Conclusion

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References[1] Shriram Sane, Varsha Karandikar, Rahul Pulkurte and Subodh Pati," Assembly line Balancing: A Case Study in Silencer Manufacturing",International Journal of Current Engineering and Technology, Vol.4, No.3 (June 2014)[2] S.Santosh kumar & M.Pradip kumar " Cycle time reduction of a truck body assembly in an automobile industry by lean manufacturing",International conference on Advances in Manufacturing & matarials engg. AMME (2014)[3] R.B. Breginski, M.G. Cleto, J.L. Sass Junior, " ASSEMBLY LINE BALANCING USING EIGHT HEURISTICS", 22nd International Conference on Production Research[4] Lamia A. Shihata," Two-sided assembly line balancing of refrigeration assembly lines",[5] S. Sathish and A.R. Lakshmanan," Assembly Line Efficiency Measurement and Line Balancing-A Case Study on Automobile Cluster Assembly Line", Research Journal of Applied Sciences, Engineering and Technology 9(8), page no. (651-654), year (2015)[6] Lim Chuan Pei, Masine Md. Tap," IMPROVING PRODUCTIVITY THROUGH LINE BALANCING - A CASE STUDY", Journal Mechanical December 2002, vol. 14,page no. (48 - 62)[7] Artun Torenli," Assembly line design and optimization "Master’s Thesis in the International Master’s programme Automotive Engineering, (2009)[8] www.tatamotors.com[9] www.sciencedirect.com

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THANK YOU…


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