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TABLE OF CONTENTS CHAPTER-1 :
INTRODUCTION
5-6
CHAPTER-2 :
METHODOLOGY
7-10
2.1
STEPS IN DEVELOPMENT OF SOFTWARE
7
2.2
SOFTWARE DEVELOPMENT METHOD
9
CHAPTER-3 :
SOFTWARE & HARDWARE INTRODUCTION
11-16
3.1
PLATFORM FOR SOFTWARE DEVELOPMENT
11
3.2
BENEFITS
12
3.2.1
Interfacing
12
3.2.2
Code compilation
13
3.2.3
Large libraries
13
3.2.4
Code re use
13
3.2.5
Parallel Programming
14
3.2.6
User community
14
3.2.7
Other benefits
14
3.3
HARDWARE AND SOFTWARE REQUIRED
15
3.4
SOFTWARE AVAILABLE FOR LINE BALANCING
15
3.5
DATABASE
15
3.6
INOVATIVE ASPECTS
16
3.7
DATA COLLECTION
16
3.8
SPECIFIC OUTCOMES
16
CHAPTER-4 :
REVIEW OF LITERATURE
17-37
4.1
LITERATURE REVIEW
17
4.2
WHY WE USE LINE BALANCING?
19
4.2.1) Simple assembly line balancing problem
20
4.2.2) U-line balancing problem
21
4.2.3) MALBP and MSP
21 1
4.3
4.2.4) GALBP
21
ASSEMBLY LINE BALANCING
21
4.3.1) Singe-Model Assembly Line
22
4.3.2) Mixed Model Assembly Line
23
4.3.3) Multi-Model Assembly Line
23
4.4
EQUIPMENT BALANCING
24
4.5
ANALYSIS
24
4.6
LINE BALANCING LEADERSHIP
25
4.7
LABOUR BALANCING AND ASSISMENT
25
4.8
EQUPMENT FAILURE
25
4.9
PROBLEM
26
4.9.1 Description of the problem
26
4.10
ADVANTAGES
28
4.11
ASSEMBLY LINE BALANCING STEP
28
4.11.1 Example
29
4.11.2 First step
30
4.11.3 Second step
30
4.11.4 Third step
31
4.11.5 Evaluation of production system
32
4.12
PRESENT METHOD
32
4.13
COMPUTRIZED LINE BALANCING
34
4.14
CYCLE OR PITCH TIME
35
4.15
TYPE OF LINE BALANCING
36
4.15.1 Intrinsic balancing
36
4.15.2 Dynamic balancing
36
CHAPTER-5 : 5.1
CALCULATION
38-40
FORMULAE
38 2
5.2
MACHINE ALLOWANCE
38
5.3
RATING
39
5.4
CYCLE TIME CALCULATION
39
5.4.1 Method 1
39
5.4.2 Method 2
39
5.5
OUTPUT PER HOUR
40
5.6
UTILIZATION
40
5.7
REQUIRED EFFICIENCY
40
CHAPTER-6 :
EXAMPLE
41-42
CHAPTER-7 :
OPERATION BULLETIN AND SKILL MATRIX
43-47
7.1
DIG.OF COMPONENT FOR PISTON CYLINDER
43
CRANK SHAFT ASSEMBLY 7.2
OPERATION BULLETIN
46
7.3
SKILL MATRIX
47
CHAPTER-8 :
DATA BASE
48-60
8.1
FRONT PANNEL
48
8.2
LOGIN
49
8.2.1 Login Administrator
49
8.2.2 User Name and Password
49
8.2.3 User Created
50
8.3
MAIN PANNEL
50
8.4
EMPLOYEE DETAILS
51
8.4.1 Add Employee
52
8.4.2 Error in Saving Details
52
OPERATION SETTING
54
8.5.1 Add Operator
55
8.5.2 Error in Adding
55
8.5.3 Operator Code Error
56
8.5
3
8.6
CHAPTER-9 : 9.1
8.5.4 Operator Breakdown
56
8.5.5 Style Number
56
8.5.6 Load Style
57
SKILL MATRIX
58
8.6.1 Employee Skill Portal
59
8.6.2 Add-Edit Skill
59
8.6.3 Adding Error
60
8.6.4 Delete Skill
60
SOFTWARE MODULE
61-66
ATTENDENCE
61
9.1.1 Update
62
9.1.2 Reset
62
9.1.3 Load
63
MANAGE LINES
63
9.2.1 Absenteeism Detail
64
9.2.2 Balance Line Type-1
65
9.2.3 Balance Line Type -2
66
CHAPTER-10 :
CONCLUSION
67
CHAPTER-11 :
LIMITATION AND SCOPE FOR FUTURE STUDY
68
11.1
LIMITATION OF SOFTWARE
68
11.2
SCOPE FOR FUTURE STUDY
68
9.2
12 REFRENCES
69-70
13 ANNEXURES
71-73
13.1 HARDWARE AND SOFTWARE REQUIRED 13.2 SOFTWARE AVAILABLE
4
71 73
CHAPTER – 1 1) INTRODUCTION
Productivity improvement is one of the prime focuses in the industry. Line balancing is the process necessary for all labor oriented industry but this is such a hectic process and takes a lot of time. These not only have this problem but also proper allocation of worker & machine is also a difficult task. Balancing assembly lines is a very important mission for manufacturing companies in order to improve productivity by minimizing the cycle time or the number of workstations. The balancing problems manage the assignment of tasks to workstations to achieve the purpose objectives. The general practice in the assembly line balancing is to assign tasks to workstations in such away each total time of assigned tasks to each workstation has an equal line cycle time. The fundamental of LB (Line Balancing) problem is to assign the task to an ordered sequence of stations, such that the precedence relations are satisfied and someone measurements of effectiveness are optimized. (Minimize the balance delay or minimize the number of work stations, etc.) Upgrading machinery, training the operators, method-study and better material handling is a continuous process towards productivity enhancement. But, at any given stage, Line Balancing can significantly increase this productivity. The mechanical industry is highly dependent on the production line supervisor for line planning and production machine operator allocation, which makes it difficult for the organization to accomplish the same task in absence of supervisor. Generally, in a factory, no records are maintained either of operator’s skill matrix, or his daily allocation; everything is saved in the supervisor’s memory. As a result, production managers and floor supervisors in factories are essential. In addition, the manager is faced with vast day to day issues such as absenteeism, machine breakdown, non-availability of accessories, etc. that gives him less time to apply to 5
line balancing. In spite of this problem human error, storing huge data and recalling when required is also a tedious job. In market any software for assembly industry is not available giving full flexibility due to complex nature of this planning. This made me to think for developing such a software or base which will help to reduce errors and give maximum flexibility in line balancing with all other options. The huge manpower of production machine operator being dealt by supervisor makes it difficult even for him/her to make effective & efficient decisions regarding operator allocation. Heavy absenteeism has recurrently resulted in assembly line bottlenecks causing the supervisor to take spontaneous & generally ineffective decisions for operator allocations. To develop a computer integrated solution for line balancing can give the better utilization of the manpower as well as machines to improve the productivity. This tool can be effectively used by the automobile industry for basic initial balancing and predicting different conditions on the shop floor, which is otherwise impossible. Apart from balancing the line, this software also provides intangible benefits like maintaining updated operators skill inventory database, timely production records etc.
6
CHAPTER – 2 2) METHODOLOGY Assembly is a process by which subassemblies, manufactured parts and components, which called tasks, are put together in the defined palaces as ordering, which called workstations to make the final products. Most of manufacturing factories will have one or more assembly lines. The assembly line balancing is probably one of the oldest problems in the industry. In a classical assembly line balancing problem, assembly task is divided into operations. 2.1) STEPS IN DEVELOPMENT OF SOFTWARE/METHODOLOGY: The following steps are following in the development of Line Balancing software/methodology: 1) To study about the process parameter of the any particular style. To study about the operation bulletin, different types of machines being used, the way by which product is manufactured, the different attachments used impacting SAM product, SAM of the different operations, production calculations etc. 2) To study the manual line balancing process. Understanding the process of the line balancing currently used in the industry. The way by which the line is balanced and impact on the productivity. Studying operator allocation on the basis of the operator efficiency and targeted production. 3) To design the proper workflow procedure for the software. Designing the user interface of the software, the proper sequence of the output of the software. As per the requirement.
7
4) Development of the database for the software. Collection of the necessary data from the company to build the database of the software. 5) To design the skill matrix. Designing of the skill matrix as per the operator, operation, SAM and the machine type and the attachment used. 6) To synchronize the database with the software. Synchronization of the database for better output with the software which can give the best results for required complication. 7) Development of the mathematical module for software. The development of the logic and calculation of the software for the internal process which can give the predicted output. 8) Testing the software. The development of the logic and calculation can be done with the process as explained below. This flow is not only confirming the process but also a system to develop a methodology for a proper balanced line. All the 7 steps are 7 key points to proceed one by one to achieve the final goal of Good production with minimum WIP. So after all the line balancing Testing is Key factor. This is important step in process of line balancing to assure that the steps taken are correct & flaw less. This also assures that the 7 steps checked closely & worked accurately on all points.
8
The above steps are also shown in the following chart (Fig-2.1): ^dhzK&WZK ^^
E>z^/^^ KE>/E >E/E'
E>z^/^K&>/E >E/E'
/DWZKs D d,K&KZtKZKt
K>> d/KEK&d
^>DdZ/y
^zEZKE/d/KEK&d^ t/d, ^>DdZ/y
s >KWD EdK&Dd, Dd/> DKh>
d ^d/E'Θs>/d/KE
Fig 2.1 shows the basic steps involved in software development plan 2.2 SOFTWARE DEVELOPMENT METHOD Following three stages has been involved in developing the software: ANALYSIS STAGE: An analysis of this problem is done in this stage.
9
This project was started with the study of a line balancing configurations and analyzed the type and amount of calculation involved in each of the line balancing module. The problem is analyzed in the industry, process flow is analyzed and all the possible outcomes and finally opted outcomes is the best suited. DESIGN STAGE: The structure is designed for the best suited outcomes. The design stands to make it user friendly and produced the required output with shorter lead time and more reliability. DEVELOPMENT STAGE: The software is finally developed as per the resultant for the analysis and design the final product is developed to fulfill the objective of the project and need of the industry. The software is checked and executed for the line balancing, and the best outcomes.
10
CHAPTER – 3 3) INTODUCTION TO SOFTWARE AND HARDWARE It is essential to study the details of the software (platform) and hardware, which is to be used in the database before starting the work. 3.1) PLATFORM FOR SOFTWARE DEVELOPMENT: The need for quality National Instruments Lab VIEW add-ons continues to grow as engineers and scientists expand the platform into new industries and applications. The Lab VIEW tools Network is a central repository for companies to list and market their product to potential customers. To help companies the best tool to meet application requirements, NI, has introduced the compatible with Lab VIEW program. Add-ons accepted to this program have been identified as reaching a high standard of function, style, documentation, and fit with Lab VIEW and are designated as member on the Lab VIEW tool network. Lab VIEW (short for Laboratory Virtual Instrumentation Engineering Workbench) is a
platform
and
development
environment
for
a visual
programming
language from National Instruments. The purpose of such programming is automating the usage of processing and measuring equipment in any laboratory setup. NI is more than 30years old company which deals in new R&D in automation & enjoys a reputation for producing a high volume of innovative new products. Lab VIEW is a proprietary product of National Instruments. Unlike common programming languages such as C or FORTRAN, Lab VIEW is not managed or specified by a third party standards committee such as ANSI, IEEE, ISO, etc. Lab VIEW programs are called virtual instruments or VI’s because their appearances and operation imitate physical instruments, such as oscilloscope and multimeters. Lab VIEW contains a comprehensive set of tools to help in troubleshoot code to write. 11
Developer(s)
: National Instruments
Operating system
: Cross-platform: Windows, Mac OS X, Linux
Operating system
: Cross-platform: Windows, Mac OS X, Linux
Type
: Data Acquisition, Instrument Control, Test Automation, Analysis and Signal Processing, Industrial Control, Embedded Design
License
: Proprietary
Website
: ni.com/labview
3.2) BENEFITS 3.2.1) Interfacing Lab VIEW is much beneficial over other development environments for the extensive support for accessing instrumentation hardware. It has included or is going to include the Drivers and abstraction layers for many different types of instruments and buses. The graphical nodes are presented by themselves. The provided driver interfaces save program development time. The abstraction layers propose standard software interfaces to communicate with hardware devices.
12
3.2.2) Code compilation Lab VIEW performs to include a compiler that produces native code for the CPU platform. It provides executable machine code by interpreting the syntax and compilation by translating graphical code. The Lab VIEW syntax is strictly enforced during the editing process and compiled into the executable machine code when requested to run or upon saving. In the concluding case, the executable and the source code are combined into a single file. 3.2.3) Large Libraries Lab VIEW package options provides many libraries with a large number of functions for data acquisition, signal generation, mathematics, statistics, signal conditioning, analysis, etc., along with numerous graphical interface elements. The number of advanced mathematic blocks for functions such as integration, filters, and other specialized capabilities usually associated with data capture from hardware sensors is immense. It also includes a textbased programming component called Math Script which can be integrated with graphical programming using "script nodes" and uses a syntax that is generally compatible with MATLAB, and also with additional functionality for signal processing, analysis and mathematics. 3.2.4) Code re-uses The Lab VIEW code allows code reuse without modifications: as long as the data types of input and output are consistent, two sub VI’s are interchangeable. National Instruments is increasingly focusing on the capability of deploying Lab VIEW code onto an increasing number of targets including devices like Phar Lap or Vx Works OS based Lab VIEW Real-Time controllers, FPGAs,
Pocket
PCs, 13
PDAs,
and Wireless
sensor
network nodes. A benefit of the Lab VIEW environment is the platform independent nature of the G code, with the exception of a few platformspecific functions portable between the different Lab VIEW systems for different operating systems (Windows, Mac OS X and Linux). 3.2.5) Parallel Programming Lab view is very easy for the programming of different tasks that are performed in parallel by means of multithreading. This is, for occurrence, easily done by drawing two or more parallel while loops. 3.2.6) User community There is a tutorial version of Lab VIEW Student Edition aimed at educational institutions for learning purposes at very low cost. 3.2.7) Other benefits of using Lab VIEW as an integrated development environment and programming language in academic research and scientific computing applications include the following: • Shorter time to prototype, time to discovery, time to deployment, and potentially time to market • Easy integration with legacy and traditional instruments (serial, GPIB, CAMAC, VME) • Easy to learn, use, maintain, and upgrade (intuitive graphical programming, using graphical constructs) • Powerful, flexible, and scalable design (open, connects to external libraries and third-party tools) • Help to develop better, faster algorithms (algorithm engineering) • One tool for design, prototyping and deployment • Multiplatform (Windows, Mac OS, Linux, RTOSs) 14
• Multidisciplinary use (same easy graphical programming language for different applications and domain experts in different disciplines in science and engineering) • Tight software-hardware integration (supports wide variety of data acquisition and embedded control devices) • Longevity (COTS-based, more than 20 years of evolution) • Ability to solve and execute complex algorithms in real time (ODEs, PDEs, BLAS-based linear algebra, signal processing and analysis, optimization, and so on) using real-world signals (A/D) • Bridge to industry – same tools used in academia and industry (academic-to-industry transition easier, technology transfer more transparent) 3.3) HARDWRE AND SOFTWARE REQUIRED:
All the details of required software and hardware have been discussed in the ANNEXURE-13.1, which provides the minimum and recommended details of hardware of the computer required to develop and run the software. As well as details of software is also provided with all the above details.
3.4)
SOFTWARE AVAILABLE FOR LINE BALANCING:
All the details and data related to this topic has been detailed and discussed in the ANNEXURE-13.2 3.5) DATABASE:
The database used for the software development in MS-Excel & Notepad, so it will be used for further references. The format of the data assists the user to 15
modify the database as per need. The data entered only at front end is saved in encrypted form at back end. This help to protect the data from any unrequired change until administrator will allow to-do so.
3.6) INNOVATIVE ASPECTS:
For the products that are manufactured as a result of many different operations, it is difficult task to balance the production line with minimum idle time. This software ascertain ideal and lean production amount that can be delivered JIT.
3.7) DATA COLLECTION:
PRIMARY DATA SECONDRY DATA
3.8) SPECIFIC OUTCOMES:
1. Can be used by the industry for basic initial balancing and predicting different as per the operator efficiency. 2. Can be used by the HR department for determining the absenteeism in the industry. 3. Can give the production output per day.
16
CHAPTER – 4 4) REVIEW OF LITERATURE This chapter will present the basic literature adopted in the work done.
4.1) LITERATURE REVIEW
Today’s business climate for automobile manufacturing industry requires low inventory and quick response systems that turn out a wide variety of products to meet customer demand. It is especially in the automobile industry that managers are trying to develop their current systems or looking for new production techniques in order to keep pace with the rapid changes in the automobile industry. In automobile enterprises a raw material is processed in different departments before becoming a vehicle. There is no doubt that the assembly department is the most important department in the whole firm. Because there are lots of different operations which are done manually, the assembly department has to be under constant control. Consequently, all line balancing processes which determine the speed of an assembly line are done in this department. Therefore, to develop a new system, good observation is needed. However, to observe real manufacturing systems is very expensive and sometimes cumbersome. The rapid rate at which the whole process takes place, the interaction between workers, and the different transition times between workers make it increasingly more difficult for a human being to make correct decisions regarding how fast each operator should work in order to continue the process, while at the same time keeping productivity high and throughput at an acceptable level. Therefore, a simulation model is an easier way to build up models to represent real life scenarios, to identify
17
bottlenecks, to enhance system performance in terms of productivity, queues, resource utilization, cycle times, lead times, etc. “Assembly line balancing or simple line balancing is the problem of conveying operations to workstation along as assembly line in such a way that the obligation be optimal in some sense” Line Balancing (LB) is a classic, well-researched Operations Research (OR) optimization problem of major engineering implication. It is one of those problems where sphere of influence ability does not assist very much: whatever the number of years used up in solving the problem, one is each time in front of an inflexible problem with an astronomic number of achievable solutions and no real direction on how to solve it in the most excellent way, unless one postulates that the old way is the best way. Here we explain an obvious inconsistency: although many algorithms have been projected in the past, and despite the problem’s practical substance, just one commercially existing Line Balancing software presently appears to be available for application in industries such as automotive. We speculate that this may be due to a misalignment between the academic LB problem addressed by OR, and the actual problem faced by the manufacturer. It appears that the gap between the available OR results and their propagation in today’s industry, is probably due to a misalignment between the intellectual LB problem addressed by most of the OR approaches, and the genuine difficulty being faced by the business. In the enlargement, we first briefly recall classic OR definitions of LB, and then evaluate how the actual line balancing problem faced by the industry differs from that definition, and why an explanation to the classic OR problem may be unfeasible in some industries. Thus, the line balancing technique is used to: 1. Minimize of the number of workstations; 2. Minimize the cycle / pitch time; 3. Maximize the workload smoothness; 4. Maximize the work relatedness. 18
4.2) WHY WE USE LINE BALANCING:
Line balancing is a manufacturing-engineering function in which whole collection of production-line tasks are divided into equal portions. A manufacture line is said to be in balance when every worker’s task takes the same amount of time. Well-balanced lines avoid labor idealness and improve productivity. All industries that have a line for example conventional assembly line and new assembly line such as heuristic and U-type and also mixed model used a small number of process such as genetic algorithms and fuzzy logic and also simulation technique to improve a few factor of line control. In other hand, managers like has a productivity and high yield in their industrial unit and for this objective get help from prior procedure to situate a machine, employer ,assign employer to machine, to opt best choose for control and work by machine. In a few industries one employer manage 2 or more than 2 machines and the outcome is output of line balancing. In another words, the organization used line balancing for raise up the rate of produce and decrease man power, idle time and buffer near machine, also used line balancing for creating more than 2 products. Real world assembly systems have need of a bundle of these extensions in many possible combinations. Thus, flexible ALB techniques are needed, which can deal with a lot of these extensions in a combined manner. Typically, there is a trade-off between flexibility and efficiency of an optimization process. Accordingly, by identifying typical combinations of extensions which frequently arise together with real-world assembly systems, procedures can be developed which exactly fit these necessities, while decreasing the required flexibility to a least amount. Moreover, practitioners might be provided with precious advices on how to use previously existing models and events for their special assembly system for that purpose this thesis is structured to show a kind of line balancing and also why the industry must be used line balancing. In another words, it is shown that how many model and technique is discovered in line balancing and each model when must be
19
used and the advantage of line balancing in the industry solving the problems happening during the line balancing in the manufacturing plants.
Assembly Line Balancing Problem
General Assembly Line Balancing Problem (GALBP)
Simple Assembly Line Balancing Problem (SALBP) SALBP-1
SALBP-1 SALBP-1
SALBP-1 SALBP-1
SALBP-1 SALBP-1
Fig4.1 Shows Classification of assembly line balancing problems (Scholl & Becker, 2006)
4.2.1) SALBP: Simple Assembly Line Balancing Problem is applicable for straight single product assembly lines, where only priority constraints between tasks are to be considered. The responsibility of Type 1(SALBP-1) problem is to minimizing the workstations for the given production rate. Type 2 (SALBP-2) is to maximize the production rate, or equivalently, to minimize the sum of idle times for each given number of workstations. Another type (SALBP-G) is used to minimize the sum of
idle
times
subjected
total workstations.
20
to
varying
production
rates
and
4.2.2) UALBP: The U-Assembly Line Balancing Problem where stations are arranged in a U narrow assembly line considers the case of U-shaped (single product) assembly lines. As a result, workers are allowed to work on either side of the U, i.e. on early or late tasks in the production method at the same time. Therefore, modified priority constraints have to be observed. By comparison with SALBP, different problem types can be distinguished. 4.2.3) MALBP and MSP: Mixed Model Assembly Lines Balancing Problem produces several models of basic manufactured goods in an intermixed cycle. Besides the MALBP, which has to allocate tasks to stations taking into consideration the dissimilar task times for the different models, relevant is the Mixed Model Sequencing Problem. MSP are used to minimize the inefficiencies (work overload, line stoppage, off-line repair etc.) to find a sequence of all model units to be produced.
4.2.4) GALBP: The Generalized Assembly Line Balancing Problems are all problem types which generalize or remove some assumptions of SALBP. This class of problems (including UALBP and MALBP) is very large and contains all problem extensions that might be relevant in practice
including
equipment
selection,
processing
alternatives,
assignment restrictions etc. In order to configuration the field, to recognize practice-relevant needs and to get better communication between inside the community and with practitioners it seems to be overdue to define a classification scheme. 4.3) ASSEMBLY LINE BALANCING The Assembly Line Balancing dependent on 3 kinds of models, they are SingleModel Assembly lines, mixed models, and multi-model Assembly lines. 21
Classification of Assembly Line Balancing Problem:
ALB Literature
Single Model
Multi-Mixed Model
Deterministic (SMD)
Stochastic (SMS)
Simple (SALB)
Deterministic (MMD)
Simple (SALB)
Stochastic (MMS)
Simple (SALB)
Simple (SALB)
Simple (GALB)
Simple (GALB)
Simple (GALB)
Simple (GALB)
SMD- Single Model Deterministic
MMD- Multi/Mixed Model Deterministic
SMS- Single Model Stochastic
MMS- Multi/Mixed Model Stochastic
Fig.4.2 shows Classification of ALB literature (Ghosh and Gagnon, 1989)
4.3.1) Singe-Model Assembly Line: Day by day changes in assembly lines used in high level production of a single product to the products without any difference and allows the profitable utilization of Assembly Lines which attracts the customers. An advanced procedure to negotiate the time and money to enable the automated setup of operations of production. Once the product is assembled in the same line and it won’t variant the setup or significant setup and it’s time that is used, this assembly system is called as Single Model Line.
22
The SMD version of the ALBP assumes dedicated, single model assembly lines were the task times are known deterministically and an efficiency criterion is to be optimized. This is the original and simplest form of the assembly line balancing problem (SALBP). Introduce other restrictions or factors (eg. Parallel stations, zoning restrictions) into the model and the problem becomes the General Assembly Line Balancing Problem (GALBP). The SMS version of problem category introduces the concept of task-time variability. This is more realistic for manual assembly lines, where workers operation times are seldom constant. With the introduction of stochastic task time many other issues become relevant, such as station times exceeding the cycle time (and perhaps the production of defective or unfinished parts), pacing effects on worker’s operation times, station length, the size and location of inventory buffers, launches rates and allocation of line imbalances. 4.3.2) Mixed Model Assembly Line: In Mixed –model line single units of different models can be introduced in any order or mix to the line. Here the setup time enough decreased between the workstations and enough to be ignored. This type of assembly line in which workers work in different models of a product in the same assembly line is called Mixed Assembly Line. 4.3.3) Multi-Model Assembly Line: In multi model lines assemble two or more products separately in batches. This type of model is used to reduce the time and money and it is arranged in batches, and this allows the short term lot-sizing issues which made in groups of the models to batches and the result will be on the assembly levels. The uniformity of the assembled products and the production system is not that much sufficient to accept the enabling of the product and the production levels. 23
The MMD problem formulation assumes deterministic task-time, but introduces the concept of an assembly line balancing multiple products. Multi –mixed model line introduces various issues that are not present in the single-model case. Model selection, model sequencing and launching rates and model lot size become more critical issues here than in single model case. The MMS problem perspective differs from its MMD counterpart in that stochastic times are allowed. However, these issues becomes more complex for the MMS problem because factors such as learning effects, working skill level, job design and worker task-time variability becomes more difficult to analyze because the line is frequently rebalanced for each model assembled. 4.4) EQUIPMENT BALANCING:
Equipment balancing attempts to ensure that each piece of equipment in the workstation has the same amount of work. It is necessary for today’s manufacturer to maximize the utilization of all available equipments. Such high utilization is usually accompanied by high inventory and is often counterproductive and may be the wrong goal.
4.5)
ANALYSIS:
Analysis is generally performed by Competent Technical Staff, if bottle neck task is in the way of good balance which should analyze the task to reduce the time it takes to perform. Begin the analysis with division of production-line work into small tasks, determination of task time standards, specification of required task sequencing and notation of constraints.
24
4.6) LINE BALANCING LEADERSHIP:
Workmen should guide the manufacture line balancing effort, so that they can act in response quickly when line imbalances (intrinsic and dynamic) collect up as a result of substitution to make a different item or changes in the productivity rate.
4.7) LABOR BALANCING AND ASSIGNMENTS:
Labor feasibility is an important element in the strategy of manufacture line flexibility related to individual skills and capabilities. Manufacture line stability is the strategy of tendency for labor assignments to be fixed. ¾
Group Technology – here one worker can hold multiplicity of tasks (automation) in a single work centre.
¾
The pressure group of entire crews from one committed line to another as the model mix changes.
¾
When the line is running smoothly, the management put into practice of purposely pulling worker’s of the line.
¾
The worker should move into help when he / she is having problem in performing his assigned task and experiencing delay due to technical problem(s).
4.8) EQUIPMENT FAILURE:
An equipment failure provides potential to shut down a production line and produces a major serious stuff. To avoid such matter it is necessary to avoid overloading of the equipments. Also the workers should be trained for the preventive maintenance of a machine and following standard operating procedures.
25
4.9)
PROBLEM:
The problem of assembly line balancing is to assign different task to individual workstations for ensuring the sum of task times at any station not exceeding the station time. Standard minute value (SMV) is generally used in the assembly industry as a predictor of assembly speed and production efficiency. In the assembly industry, the standard minute time derived from the work study method is generally assumed as a constant for line balancing. However, a lot of factors cause variations on operational time of the same task such as the raw parts and sub materials, performance of the machinery, working environment and
quality level of the
product. 4.9.1) DESCRIPTION OF THE PROBLEM: An assembly line consists of (work) stations k = 1,...,m usually arranged along a conveyor belt or a similar mechanical material handling equipment. The work pieces (jobs) are consecutively launched down the line and are moved from station to station. At each station, certain operations are repeatedly performed regarding the cycle time (maximum or average time available for each work cycle). In many automobile industries, standard push production systems with dozens of workers are being reorganized into straight assembly lines. In assembly departments the Standard time (St) for each operation is calculated by the sum of the base time (Bt), the fatigue allowances (Fa) and the idle time (It). The base time consists of the stopwatch time (Sw) and the performance rating (Pr). It is calculated as follows; St = Bt + Fa + It = Sw × Pr + Fa + It ………………………(4.1)
26
The line balancing problem of assembly departments is solved by using St, and it’s assumed that all of the same operations are processed equally. However, in reality, all operations are completed at different times because of their stochastic structure, and the stochastic of operations makes it almost impossible to follow a fixed time pattern. The following assumptions are used to define the problem: •
The assembly line is never starved.
•
Set-up times are not taken into consideration.
•
Because in a real system the setup process is usually accomplished at the
end of the working time. •
No maintenance process is performed during the working period.
•
Transportation of raw materials is performed by workers who aren’t
used for assembly operations. Line Balancing is the production time of such allocation of machine and / or people so that a requirement to produce a minimum possible production time. Upgrading machinery, training the operator, method study and better material handling is a continuous process towards productivity enhancement. But, at any given stage, scientific ‘Line Balancing’ can significantly increase this productivity. Generally, in a factory, no records are maintained either of operator’s skill matrix, or his daily allocation; everything is saved in the supervisor’s memory. As a result, production manager and floor supervisors in factories are indispensable. In addition, the manager is faced with overwhelming day to day issues such as absenteeism, machine breakdown, non availability of accessories, etc. that gives him less time to devote to line / batch balancing.
27
Line balancing problem are well known application of industrial engineering departments. Different kinds of line balancing algorithms have been applied for many years in the automobile industry. However manual operations oriented system of this sector makes it difficult to predict upcoming events when the production system is modified. 4.10) ADVANTAGES 9 To give authentic response to the Buyer on Production Schedule. 9 Eliminates trial & error delay for balancing during Style change. 9 Objective, Scientific, Human-independent Line Balancing Solution. 9 Point out Bottleneck Operators. If manpower is used too much in a plant, it has a big share in total product cost. It is necessary to minimize worker idle time for total production cost and for worker motivation. This software will determine the production amount with the minimum idle time. In the automobile industry, it is essential to form a new production line for each order, and also the number of worker is changed according to the complexity of the order, the number of operations, throughput etc. The thing which should be done during the installation of an assembly line is as: 9 To define a standard time for each operation 9 To balance the production line for each order 9 To keep the utilization rate at a maximum for each operator 9 To complete all these steps in one week before production begins 4.11) STEPS FOR ASSEMBLY LINE BALANCING: Assembly Line Balancing can be defined as a Step By Step Process of •
Optimum operation breakdown of a vehicle
•
Determining time values for each operation (using either time study or Predetermined Motion Time Systems) 28
•
Calculating total workforce requirement based on target, predicted line utilization, predicted attendance and avg. efficiency (rating) of operator
•
Allocate available resources (operators who are present from skill inventory) to requirements (operations), so that 1. Target is fulfilled 2. Priorities of operations are met 3. Operators are assigned to operations they do best 4. Idle time for operators are minimized
In short balancing a line means trying to bring equilibrium in output among operations in a sectionalized working scenario. 4.11.1) EXAMPLE: A small example will illustrate the principle further. Let us consider there are five operations in a vehicle. B &D operations are dependent on A & C, respectively, E id dependent on both B &D. A & C can start simultaneously. Time value (to be precise SAM value) for operation A is 3 minute. So operation A will complete 20 pcs./hrs.. Similarly capacities for other operations are like C- 30 pcs/hrs., D- 40 pcs/hrs., and E – 30 pcs/hrs., Minimum how many operators do we need for every operation to have a balanced production? ;ϮϬƉĐƐͬŚƌͿ
;ϯϬƉĐƐͬŚƌͿ ;ϯϬƉĐƐͬŚƌͿ
;ϯϬƉĐƐͬŚƌͿ
;ϰϬƉĐƐͬŚƌͿ
FIG 4.3, shows no. of workstations and line balancing in any plant 29
Simple LCM will solve the problem like A needs 6, B,C and E needs 4 each and D needs 3 operators to balance the line and give an output of 120 pcs/hr. Here no operator will be idle at any point of time. In actual shop floor condition the situation is much more complex than above because: • Numbers of operations in a vehicle are quite high. • All operators do not work at same efficiency. • Operation timings are not in round figure, (i.e. as per time study actual capacity may be 23 pcs/hr, 37 pcs/hr, 41 pcs/hr. Etc.). To solve this type of case using only LCM principle will lead to unrealistic solutions.
So we need some practical ways out: 4.11.2) FIRST STEP: We have a tendency to round off the operation timing as far as possible (i.e.23 will be treated as 20 pcs/hr. and 37 will be treated as 40 pcs/hrs and so on). A production manager usually prefer to follow a ‘Hand to Mouth’ system while feeding his lines rather than working on the ‘Processed Stock’. For example if a 27 pcs/hr operator feeds another 30pcs/he operator, then the later operatior will be idle for 6 minutes some operators are under- utilised (eg. When 23 pcs/hr capacity operator was asked to produce only 20 pcs/hr) and some are over burdened (eg. 37 pcs/hr was asked to produce 40 pcs/hr). That is why in shop floor always we have some under-utilised operators and some overburdened operators however balanced the line might be. 4.11.3) SECOND STEP: Building up a WIP between operations so that operators are not working with for every hours of operation. If 30 pcs of WIP is provided between the same 30
two operators then both can work at their own pace achieving respective targets continuously for 10 hrs before the total WIP runs out. Popular practice is to use extra hands or non-productive times (break-hours, overtime) to replenish the WIP. Apart from covering for such imbalance WIP is also used as a buffer in case of machine breakdown or operator falls ill, etc. 4.11.4) THIRD STEP: Sometimes the actual operations SAM values are diverse (eg. 17 pcs/hr, 37 pcs/hr, 20 pcs/hr, and so on) that we need to club or split operations based on required output or available machinery. Clubbing of operations are comparatively easier and operations that require similar machines (similar attachment also) can easily be clubbed even through the material flow in the floor because jigsaw. Splitting of a time consuming operation may require operation re engineering and require reasonably good command over vehicle construction technique. After completing above steps the supervisor calculate operator efficiency required for every operations and then operator assign jobs (operations) based on what can be best. For example if work content (SAM Value) of operation 1 is 0.7 min and Target is 60 pcs/hr, then (0.7 x 60) = 42 min of work to be accomplished per hrs. this means we need to select operator in operation 1 with (42/60) x 100 = 70 % rating to meet the target. From the skill inventory database an operator is chosen who has 70% rating (or closer) for this operation. Similarly operators are chosen one by one for all operations. If there are 10 operations for the style and average operator is multi skilled to do 2 operations each, there can be many ways in which operators can be allocated jobs (based on different permutations). Manually checking all operations is impossible for any production manager or supervisor. As a result allocation is done hypothetically based on intuition, gut feel, and past experience, but no science. 31
4.11.5) EVALUATION OF PRODUCTION SYSTEM: Any production system has four factors, which make up the system. Processing Time + Transportation Time + Temporary Storage Time + Inspection Time = Total Production Time ……………………….. (4.2) Processing time is sum total of working time of all operations involved in manufacture of a vehicle. Transportation time involves the time taken to transport semi finished or finished object from one department to another or from one operation / machine to another. Temporary storage time involves during which time the vehicle is idle as it waits for next operation or for completion of certain parts. Inspection time is time taken for inspecting fully finished object before dispatch. The main aim of any planning is to achieve minimum possible. 4.12) PRESENT METHOD: The assembly line supervisor is usually the one to assign operations to workers so as to balance the overall line cycle time. As the industry now moves toward fashionable products, it must adjust their operations to work on much smaller lot sizes. This unavoidably leads to shorter preparation time for each production lot. This research focuses on developing a practical methodology to assist assembly line supervisor perform effective line balancing. In automobile industry a product is manufactured through a series of operations. Each operation must be performed on a machine / tool with a specific machine setting, & attachment. Manufacturing a product always requires different types of production machines and different parts of different characteristic, making it difficult to assign a worker to perform operations on just a single machine.
32
There is a maximum number of machines that each worker can use for a particular product. Denotes the line configuration of the problem considered in this research of which each worker can use at most three different machines. For the ease of working, identical machines of different settings will be treated as different machines. The worker therefore needs not to adjust the setting every time he/she performs an operation. The decision making scheme developed in this research is to assign operations and their corresponding machines to a team of workers so that the line cycle time is minimized. The optimization model takes into account workers’ skill levels as well as the constraint on the number of machines at each station (worker). Each operation can be classified as a skill type. Each worker in the team is evaluated for all these skills on standardized tests. The ratings based on time required to perform such skill to meet acceptable quality level is given to each worker for each skill. This rating system allows for incompetent workers who cannot perform certain skills as well. The solution approach is divided into two phases. In the first phase, a multi-stage integer programming model is developed to assign operations, corresponding machines and their settings to stations considering standard operation times, station by station. Parallel stations are allowed so as to improve overall line cycle to as well as to use the required number of workers. Then in the second phase, another integer programming model is used to assign workers to stations based on their aptitudes to minimize the overall line cycle time. Just-In-Time production is an important target in plant, which can be achieved by consideration of lean production criteria. One of these criteria is line balancing, which enables a smooth work flow. Also in order to minimize the ideal time that cannot be filled at the workstation, it should carry the prospect of ascertaining an ideal production amount. Vehicle production involves a various numbers of operations that exhibits different features. Consequently, Line Balancing in vehicles production is tackled as a single problem in order to construct this programming package. According to the
33
fundamentals of Lean production, operations are grouped as modules and it’s aimed to achieve synchronization throughout and between these modules. This software ascertains ideal production amount where the total efficiency of worker is maximum. It also supplies the details of workload (name of the operations, the machine to be used, and efficiency) of worker corresponding to these production amounts and the % of total module efficiency. With this software, the production amount with minimum ideal times can be ascertained as well as the lost time in the desired production amounts. This software is designed to adapt to any production scheme involving complex operations easily. 4.13) COMPUTERIZED LINE BALANCING The whole process needs cumbersome (if not complex) calculations which can be easily and quickly done in computer. Not only does the line need to be balanced once, but absenteeism and WIP management requires continuous re-allocation of workers and this is where computer software can help. A manufacturer sends an email mentioning operation wise Standard Allowed Time (SAM) for the to-be-produced style and inputting other necessary information in an excel file. The dot com emails back Batch/Line-Setting solutions to the manufacturer. The Solver Software at LineBalance.com is powered by Genetic Algorithm. It simultaneously optimizes on • Maximizing number of product per hour • Minimizing operator cost per product • Maximizing operator efficiency. The Algorithm outputs about 10 diverse optimal Batch/Line-Setting for the to-beproduced-style. Depending on absenteeism and machine breakdown, one particular Batch/Line-Setting solution is to be taken for production.
34
A Batch/Line-Setting solution gives, for every single operator, • Operations to be performed • The number of such operations for an hour-slot • Time taken for the above • Machine to be used • Hence, it gives per hour track ability The Line Balance software should not be mistaken as a replacement for line supervisors or production managers. Rather, it is a decision support system to help the existing supervisor/manager to take rational decision at a lightning speed. The Batch/Line-Setting solution is also useful for committing to the buyer on production schedule and obviating trial and error. 4.14) CYCLE TIME OR PITCH TIME
The pitch time is the speed at which parts or products flow from process to process on a manufacturing line. “It is a theoretical operation time each operation should take for planned balance line” For example, if the pitch time is 50 sec., the materials for one product are introduced to the production line every 50 sec., and every 50 sec., one object is finished. Cycle time is used for calculating optimum worker & efficiency (as in attached excel sheet)
CYCLE / PITCH TIME =
SAM
OR
NO. OF OPERATOR
AVAILABLE HOURS REQUIRED PRODUCT PIECES
………………………………… (4.3)
35
4.15) TYPE OF LINE BALANCING 4.15.1) INTRINSIC BALANCING: The Intrinsic balancing is close match to the required efficiency to the available efficiency. 4.15.2) DYNAMIC BALANCING: Dynamic Balancing aerations in work time unrelated to product mix. Dynamic imbalance is short-term and occurs over period of minutes, hours or, at most, a few days. Here the operator with best efficiency is selected. OPERATION SAM MACHINE
TARGET
OPERATOR
PCC
PERFORMANCE
/ TOOLS
REQUIRED A
1.5
SPANNER
40
100
B
1.2
SPANNER
40
80
C
1
SPANNER
40
66
Table 4.1 shows selection of operator with best efficiency AVAILABLE OPERATION RAM
SHYAM
RAGHU
UMESH
A
70
105
------
140
B
80
------
100
------
C
120
70
100
70
Table 4.2 shows availability of operators and efficiency 36
PLANNED OPERATOR OPERATIO
SA
MACHIN
PERFORMANC E REQUIRED
INTRINSI
DYNAMI
C
C
N
M
E / TOOL
A
1.5
SPANNER 100
SHYAM
UMESH
B
1.2
SPANNER 80
RAM
RAGHU
C
1
SPANNER 66
UMESH
UMESH + RAGHU
Table 4.3 shows selection of operator by work type COMPARITIVE STUDY OF DYNAMIC & INTRINSIC BALANCING INTRINSIC
DYNAMIC
BALANCING
BALANCING
MORE
LESS
LESS
MORE
HEAVY ABSENTISM
NOTPREFERED
PREFERED
SUPERVISOR SKILL
LESS HEADECHE
MORE HEADECHE
WIP MANAGEMENT
EASY
DIFFICULT
MATERIAL
LESS
MORE
LESS
MORE
PARAMETER
NUMBER OF PEOPLE REQUIRED MOVEMENT OF OPERATOR
MOVEMENT WORKMAN SHIP LOSS
Table 4.4 shows comparative study of dynamic & intrinsic balancing
37
CHAPTER – 5 5) CALCULATION: 5.1) FORMULAE The following step shows the calculation & formulae that used for development of assembly line software: PFD (PERSONAL FATIGUE ALLOWANCE) = 14% OPERATORS =18% FOR HELPERS (PERSONAL & FATIQUE= 11%, CONTINGENCY= 3%) 5.2) MACHINE ALLOWANCE : S.NO
MACHINE / TOOL
PERCENTAGE ALLOWANCE
1
WRENCH
9
2
SPANNER
14
3
SCREW DRIVER
9
4
SOCKET
7
5
AIR SPRAY GUN
11
6
AIR VACCUM GUN
14
7
WELDING MACHINE
14
Table 5.1 shows the Machine / Tools user along with the parentage allowance BASIC TIME = OBSERVD TIME
X
(RATING / 100)
…………… (5.1)
STD. TIME = BASIC TIME + M/C ALLOWANCE + PFD ALLOWANCE …………… (5.2) 38
STD. ALLOWED MINUTES (SAM) = STD. TIME
/
60 …………… (5.3)
TARGET / DAY
=
(480 X NO. OF OPERATORS) / SAM …………… (5.4)
5.3) RATING % =
X
(SAMX60)
(1+ (M/C ALLOWANCE+ PFD ALLOWANCE/100))
100 OT
…………… (5.5) 5.4) CYCLE TIME CALCULATION:
5.4.1) METHOD 1: CT =
SAM NUMBER OF OPERATOR’S / OPERATION
5.4.2) METHOD 2: IF REQUIRED PRODUCTION & HOURS AVAILABLE GIVEN: VEHICLE / HOUR AVAILABLE =
REQUIRED PRODUCTION PPC AVAILABLE HOURS
TOTAL MINUTES REQUIRED / HOUR = VEHICLE / HOURS AVALIABLE X TOTAL MINUTE AVAILABLE IN 1 HOUR = 60 MANPOWER REQUIRED TO COMPLETE THE ORDER =
TOTALMINUTE REQUIRED / HOUR 60 39
SAM
MANPOWER AT GIVEN UTILISATION % =
MANPOWER REQUIRED TO COMPLETE THE ORDER X 100 UTILIZATION %
CYCLE / PITCH TIME
=
SAM
NUMBER OF OPERATOR’S / OPERATION’S (Putting all values from Equation)
=
HOURS AVAILABLE X
UTILIZATION %
REQUIRED PRODUCTION X 100
CYCLE TIME PRODUCTION =
60 CYCLE TIME
5.5) OUTPUT / HOUR =
60 SAM
5.6) UTILIZATION =
MANPOWER USED MANPOWER PLANNED OR REQUIRED
5.7) REQUIRED EFFICIENCY OF WORKER TO MATCH CYCLE TIME =
CYCLE TIME PRODUCTION / HOUR X 100 OUTPUT / HOUR
40
CHAPTER – 6 6) EXAMPLE: On the basis of formulae discussed in the last chapter the following problem is worked out: GIVEN THAT:
LET REQUIRED PIECES ARE = 1920 WORKING HOURS = 8HOURS / DAY PER SHIFT
DAYS AVAILABLE TO COMPLETE PRODUCTION = 5
SAM = 10
MANPOWER UTILIZATION IS = 80 % SOLUTION:
PRODUCT / HOUR AVAILABLE =
1920
= 48
8X5 TOTAL MINUTE REQUIRED /HOUR = 48 X 10 TOTAL MINUTE AVAILABLE IN 1 HOURS = 60 MANPOWER REQUIRED TO COMPLETE THE ORDER = 480 / 60 = 8 WORKER MANPOWER AT GIVEN UTILIZATION % = (8 X 100)/80 = 10 WORKER 41
CYCLE / PITCH TIME
=
10
= 1 MIN
10
CYCLE TIME PRODUCTION =
60 / 1 = 60 PCC / HOURS
LET SAY SAM OF GIVEN OPERATION IS = 0.7
REQUIRED OUTPUT = 0.7 X 60
=
42 PCC/ HOUR
REQUIRED EFFICIENCY OF WORKER TO MATCH CYCLE TIME
=
42 X 100
= 70 %
60
So now software matches the available worker efficiency from skill matrix with this calculated manpower efficiency & give the best match.
42
CHAPTER – 7 7) OPERATION BULLETIN AND SAM FOR PISTON CYLINDER
CRANK SHAFT ASSEMBLY: 7.1) A Simple Dig. of Components will be Useful in Getting a View of Piston Cylinder Head Assembly :
Fig 7.1 shows clear assembly view Piston Cylinder Head Assembly
43
Fig 7.2 shows the Piston,Cylinder,Connecting Rod and Cranl Shaft Assembly
44
Fig 7.3, shows the side view of Assembly
Fig 7.4,shows the assembly of wristpin and rings
45
7.2)
OPERATION BULLETIN
Sl.No.
Operation Description
Code
1
Cylinder Piston Gudgeon Pin Ring
CPGPR
2
Piston Rust Pin
3
Machine / Tool
Standard Minute Value (SMV)
P Chiesel
0.50
PRPA
Helper Table
0.24
Piston Ring Set
PRSA
S Nut
0.45
4
Clip Piston Ring 15mm
CPR15
Socket
0.50
5
Cylinder Assembly
CYLAS
Wrenches
1.05
6
Stud For Cylinder Head Mount
SCHM
P Chiesel
0.40
7
Bolt M-6 X 70
BM6A
Spanner
0.25
8
Pin Dowell 12x 20
PD1220
Screw Driver
0.20
9
NUT SPL 14mm
NSPL14
Wrenches
0.60
10
Gear Primary Driver
GPD1
Wrenches
0.45
11
Key For Gear Driver
KFGD
Pressing Table
0.55
12
COLOR 18 Mm
CLR18
P Chiesel
0.400
13
Ball Bearing Ra28x68x18
Socket
0.650
14
Crank Shaft Ass With Bearing
CFAB
Helper Table
0.350
15
Ball Bearing Radial37x72x17
BBRA37
Socket
0.51
16
Key Wood Rough25x14x4
KYWR
Allen Key
0.25
17
Nut M6
NM6A
Allen Key
0.60
18
Spring Washer
SWA6
Socket
0.50
19
Plain Washer
PWA4
Socket
0.50
20
Gasket Cylinder
GCA9
Helper Table
0.60
21
Damper Cylinder
DCAR7
Allen Key
0.75
BBRA28
46
22
Cap Ac Generator
CPACG
Helper Table
0.75
23
O Ring 13x3
ORNG13
P Chisel
0.85
24
Pin Dowell 8x12
Screw Driver
0.70
25
Gasket LH Crank Case
GLHCC
Socket
0.70
26
Bolt Fanage SH 6x32
BFAD
Spanner
0.70
27
Oring 8 X3
ORN8
P Chisel
0.55
28
Cap30 Mm
CAP30
Screw Driver
0.50
29
Bolt Flange SH 6x32
Spanner
0.58
30
PID96
BFSA32 INSPN
Inspection
Checking table
TOTAL
2.00 18.14
Table 7.1 shows opération description and SMV of opération 7.3) SKILL MATRIX
FIG 7.5 shows screen short of a skill matrix 47
CHAPTER – 8 8) DATABASE: The following pages shows; 8.1) FRONT PANEL
8.2)
LOGIN
8.3) MAIN PANEL
8.4)
EMPLOYEE DETAILS
8.5) OPERATION SETTING
8.6)
SKILL MATRIX
8.1) FRONT PANEL
FIG.8.1 shows front panel for the software The front panel is the user interface of the VI. This is the first window to start the Line Balancing Engine. By clicking directly to this page user directly access to LOGIN page. This will show the total details of software, company for which it is prepared & copyright of the software. 48
8.2) LOGIN
FIG.8.2 shows login panel for the software In computer security, a login or logon refers to the credentials required to obtain access to a computer system or other restricted area. Logging in is usually used to enter a specific page, which trespassers cannot see. Once the user is logged in, the login token may be used to track what actions the user has taken while connected to the site. The register user can log in the software by providing the user id and password while the new user can register him by providing the data in the pop-up window. In this software the different ways to login are: 8.2.1) LOGIN ADMINISTRATOR Once you've created an administrator account for your domain, you can reach your administrator control panel to activate services and adjust other settings. Process to register new user by Administrator LOGIN gives permit to add user, delete user or view user details. 8.2.2) USER NAME AND PASSWORD: This window provides entry details for the new user as user name, password, and type of user as administrator, operator, and supervisor. 49
Administrator will be given all the powers to open/ view all the tabs and edit all the entered details of users, where as operators and supervisors’ will have limited powers to use this software. 8.2.3) USER CREATED Finally, by the permission of the user (click OK), will create the new user to login.
8.3) MAIN PANEL
FIG.8.3 shows login panel for the software Main panels the first user interactive window from which user can select the different option as per his requirement. Main panel allows user to select the required module. User can select any module from this window by clicking the required button. The main content of this window are 50
¾ Employee details ¾ Line balance configuration ¾ Operator attendance & ¾ Manage lines By clicking appropriate option user can edit, feed, observe and can print the records. 8.4) EMPLOYEE DETAILS
FIG.8.4 shows employées détails panel for the software This will be generally used by the HR officials to keep the employee/operator details for their convenience. This window will be consisting of: ¾ ADD: tab enters the new employee & to save the list in the database. ¾ EDIT-DELETE: tab removes the employee who left company & also edit their existing details ¾ PRINT: tab prints the employee details. ¾ EXIT : tab move on the next window / main panel 51
In this window data should be maintained for employer as ID, Name, Designation, Date of joining, Address, Unit. When an employee joins or leaves the company database is updated. 8.4.1) ADD EMPLOYEE
FIG.8.5 shows update employées détails panel for the software When user will click on the ADD option small pop-up window will open containing the details of the operator. User has to feed all the fields in this window. After click on OK all data entered will be saved in database. 9 Employee ID must be unique. It is not case sensitive. 9 Date of joining is auto saved and will take current date, if not specified user 52
After clicking OK the details will be saved into the database. 9 Employee ID must be unique. It is not case sensitive. 9 Date of joining is auto and will take current date, if not specified by user. 8.4.2) ERROR IN SAVING DETAILS
FIG.8.6 shows error in saving employées détails panel for the software The employee ID assigned to the employees will remain unique for the particular operator. The software will not allow assigning the same employee ID to the different employee until unless he/she has deleted from the database. The software will prompt the user shown above.
53
8.5) OPERATION SETTING
FIG.8.7 shows opertions setting panel for the software Operation setting window allow user to insert any number of operation in the operational portal and to generate the operation breakdown for any style. After selecting the operation the code will automatic appeared at the top of the operation portal. This will help the user to know about the existing code for any operation & help them while adding new operation. This is also helpful in preparing operation breakdown for any style. It also shows total SMV of the product for the style. 54
8.5.1) ADD OPERATOR IN PORTAL The highlighted part on the left side of the window is called as Operation Portal (fig8.7) where user can add the operation by clicking the ADD button downside the operational portal. One small popup window will open where user has to feed the operation details such as: 9 Operation code
9 Operation name
9 Machine
9 SMV
After clicking OK the operation will save in to the database and will be executed in the operation portal. Remove option is used to remove the option from the operation from the portal which consequently delete the operation from the portal as well as database. It is simple and done by selecting and removing.
8.5.2) ERROR IN ADDING IN PORTAL Whenever users keep any field empty the software will inform user that required field is empty by error message, this will help user to do error free work. 9 Operation code is non case sensitive & takes all data in upper case automatic. 9 Operation is non case sensitive & takes all data in lower case automatic. 9 Machine code is non case sensitive & takes all data in upper case automatically. 9 SMV is in the range from 0.001 to 60. This will allow user to take any value between these two. If user wants to save without changing SMV, popup inform user that is he/she want to save SMV 0.001 or want to change it. This will avoid wrong entry of SMV.
55
8.5.3) OPERATION CODE ERROR Operation code will be unique for each operation according to which it will help user to different operations. The operation code will be used by the next modules of the software to differentiate the operation, operator efficiency, operation breakdown of the particular style; hence operation code is most important. Precaution has been taken so that this will not repeat & if it happens popup will show the alert. 8.5.4) OPERATION BREAKDOWN DETAILS The rightmost part of the window is the operation breakdown details where user can generate the operation breakdown for any style. User has to select operation from the operation portal and click ADD in between it; this moves operation to the right side window. The selected operation in the operation portal also executes its code on the right top of the operational portal. In the table, user can add any number of operations as per the style and style and along with it, software will also show the Total SMV of the style at the top of the table. User can drag and drop any operation at required sequence. User can also remove operations from the style. User has to click SAVE to save the style in the database. 8.5.5) STYLE NUMBER After adding the appropriate operation to the table user has to give the name to that particular style. Whenever user keeps the field “style number” empty software will alert user to enter the style number. After entering the style number user have to click SAVE to save the style number in the database. This style number is also unique number & if user same style code this will show, “style no. already exists, do you want to replace it”. If there is a small change in OB 56
then user can load old style, make change and save with new style number. So it will help in doing same work again and same time. 8.5.6) LOAD STYLE
FIG.8.8 shows confirmation of the opérations setting panel for the software User can find the LOAD option at the bottom of the table which is used to retrieve the styles which already have been stored in the database. One popup window will open which will give the list of the all saved in the database. User can select the required style number. User can also edit the existing style number by adding style number. RESET button is used to reset the table, all the operation will be removed from the table. EXIT will move user to the main panel. 57
8.6) SKIL MATRIX
FIG.8.8 shows skill matrix panel for the software User can ADD number of operations for the selected employee in the Employee Portal. To add more operation for the selected employee, user has to select from the operation and click on the ADD-EDIT button. This module is one of the most important modules of software, where user has to develop the database of the operator efficiencies for the different operation. This window contains of the operator portal and employee details. As user click on the required operator in the operator portal, it will be executed with its employee ID and name in the employee details highlighted above. User can input any number of operations in the table as per the operators skill. This will generate skill matrix. 58
8.6.1) EMPLOYEE SKILL PORTAL User can ADD number of operations for the selected employee in the Employee Portal. To add more operation for the selected employee, user has to select from the operation and click on the ADD-EDIT button (fig8.8). When user click the dropdown menus in the table it will show all the operations which already existed in the operation portal of the previous window. User can select the operation as per the operator’s skill. It will automatically take the operation code and the operation name. By filling the appropriate in front of the operation the software will calculate the output per hour of the operator for that particular operation. These details can be added to the database by clicking ADD/EDIT button. Same button can be used further to edit the details of the operator, when required to update the skill matrix. 8.6.2) ADD-EDIT SKILL User can ADD number of operation for the selected employee in the Employee Portal. To ADD more operation for the selected employee, user has to select from the operation and click on the ADD-EDIT button (fig8.8). After clicking it will save that operation for the selected employee. When user will click the operator from the operator portal it will retrieve the all details of the operator which have been already saved to the database. User can again input the new operations or can edit the existing operations. User has to click ADD/EDIT button every time when he edits or adds the operation in the table, which will give the confirmation that the details has been added to the database. As the module is very important and will be used to balance the line; user to balance the line; user must be very careful while filling the details in the skill matrix. 59
8.6.3) ERROR IN ADDING SKILL User can add any number of operations for the selected employee in the employee portal. To add more options for the selected employee, user has to select from the operation and click on the ADD-EDIT button. Software will alert user whenever he/she will input the same operation to the same operator. Software also alert user when he/she will not enter efficiency in front of the operation, this will show the message “efficiency should not be zero”. This all LOGIN is given backend to do, which helps user to do error free entry. After clicking it will save that operation for the selected employee. 8.6.4) DELETE OPERATOR SKILL User can add any number of operations for the selected employee in the Employee Portal. To add more operation for the selected employee, user has to select from the operation and click on the ADD/EDIT button (fig8.8). After clicking it will save that operation for the selected employee. Deleting the operation from the table will delete the selected operation and remaining operations will remain as it is in the database for the particular operation. By clicking the Delete operation button, one popup window will open where user can select the operation to delete. It will execute only those operations which are assigned to that operator. Click OK to delete the operation. EXIT will move to main window without saving any changes. User has to click on ADD/EDIT to confirm that the details have been added to database.
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CHAPTER – 9 9) SOFTWARE MODULE: The following pages shows; 9.1) EMPLOYEE ATTENDANCE 9.2) MANAGE LINES
9.1) EMPLOYEE ATTENDANCE
FIG.9.1 shows employee attendance panel for the software This window will be used by the HR peoples who will feed the list of the present and absent operator on that day. This window will show the ID and name of all employees which will be updated from the employee details module. By default it will present the entire operator, to make the work fast and easy. Only HR persons have to follow absentees & do updates. 61
9.1.1) UPDATE ATTENDENCE
FIG.9.2 shows employee attendance update panel for the software The dropdown menus highlighted in the right side is used to update the employee attendance. By selecting the absent employee user has to click UPDATE & it will turn the employee red and mark it as absent. Same button can be used to mark present also in case somebody by mistake as absent or come late. It will also give the total absent and present number of the employees in the right side highlighted 9.1.2) RESET RESET option will reset the window and mark everyone as a present. This will be used to refresh the data. (fig9.2) 62
9.1.3) LOAD LOAD option will load the previous attendance which has been saved in to database. This option will help user to make further changes when any operation come later. This will recall data even window is closed & again open (fig9.2). When user again open the window it shows all present & as he/she click LOAD button, it will give the latest updated list from database.
9.2) MANAGE LINES
FIG.9.3 shows manage line panel for the software Manage line will show the best possible options to set the balance line. This window retrieves data from the module to balance the line. This module is totally based on the calculations shown above. The basis of this calculation is the pitch time and the required efficiency of the operator for the particular operation.
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The pitch time is calculated on two bases and both options are available. Selecting one will disable the other. The lower & upper efficiency range will help to define the worker to be selected is in range or out of it. The row colour will appear in three as shown and allow user to take decision. 9.2.1) SHOW ABSENT EMPLOYEE
FIG.9.4 shows load employee attendance panel for the software This window will show the absent employees from the line selected. This window retrieves data from the attendance module to balance the line and to select the replacement for the absent employee.
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9.2.2) BALANCING WITH TARGET EFFICIENCY
FIG.9.5 shows different line balancing technique-1 panel for the software This module balances the line by two different methods. FIRST ONE is based on the production required and SECOND is based on the workers available or SMV required. User has to input the target efficiency of the factory, required production, day’s available, working hrs/days and manpower utilization. After that user has to fill the lower and upper efficiency range for the selection of the operators. After filling all these fields user has to click BALANCE LINE button which will select the best operator within the range and gives the best possible option for the operation where it doesn’t find the operator in the range. The indicator above the extreme right help user to identify the selected, already allocated and more than one operator required. 65
9.2.3) BALANCING WITH WORKER AVAILABILITY
FIG.9.5 shows different line balancing technique-2 panel for the software Second one is the worker available & SMV. User has input the target efficiency of the factor, SMV & Manpower available for particular line. Again user has to fill lower and upper efficiency range for the selection of the operators. After filling all these field user has to click BALANCE LINE button which will select the best operator within the range and give the possible for the operations where it doesn’t find in the range. The indicator above the extreme right help user to identify the selected, already allocated and more than one operator required. 66
CHAPTER – 10 10) CONCLUSION: Labor flexibility is the key to valuable resource management. The idea of worker’s assessment and doing minor repair work on their own equipment possibly decreases the risk of apparatus failure. Production-line balancing study tends to employ thought and ingenuity to change circumstances. Production-line design and operation is more art than science. Selecting a suitable set of balancing mechanism is a part of work cell design and it must be coupled with many other decisions for the organization to function well. Increased competition, product diversification, and excellence in service have forced vehicle manufacturers to increase productivity, reduce costs, adapt to demand cycle and improve quality. Only those units will survive which are competitive an efficient in all respect. Indian industry has specific production manufacturing systems. Majority of manufacturers follows assembly/ line/ throughput manufacturing system. Because of labor intensive, skill based industry it is absolute necessary to have efficient assembly/ line production system. Effective working of software will reduce the load of planning department & also give the best line for efficiency & productivity. I have identified a number of aspects of the line balancing problem that are vital in industries such as automotive, yet that have been either neglected in the OR work on the problem, or handled separately from each other. According to my experience, a line balancing tool applicable in those industries must be able to handle all of them simultaneously. That gives rise to an extremely complex optimization problem.
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CHAPTER – 11 11) LIMITATION AND SCOPE FOR FUTURE STUDY 11.1) LIMITATION OF SOFTWARE • The software does not support multiple user access. • The software is dependent on updated Skill matrix. If the Skill Matrix in not updated on regular basis the software will not be able to give most efficient solution. 11.2) SCOPE FOR FURTHER STUDY The software being used has a vast scope for further modification. 9 Linking new technology as RFID (Radiofrequency Identification) with this software will make it more accurate & fast, as far as data feeding concerned. 9 The software would save the time by joining it with the Swipe Card Reader or Thumb Reader to mark the attendance of employee fast. 9 Connecting the software with hardware for automatic data capturing, would be helpful in auto updating of skill matrix. This will reduce the company dependency on the supervisor to get the database. 9 The software can be upgraded to next level by including a module for payroll generation for each operator, since the attendance data base & efficiency matrix will provide data to generate the payroll module. 9 The module would also include incentive system on the basis of each operator’s performance which would ultimate be based on the efficiency of operator. The software would track the attendance of each operator & would inform the designated authority if any operator is absent for more than allowed number of days. 68
12) REFRENCES • Chuter A.J., A book on Introduction to clothing production management, Blackwell Publishers Inc.,16 June 1995 • Cooper Cary L, Argyris Chris, A book on The Blackwell encyclopedia of management, Blackwell Publishers Inc., 1998. • Esmaeilian G.R., Ismail N., Sulaiman S., Ahmad M.M.H.M., M. Hamedi (2009). Allocating and Balancing of Mixed Model Production through the Parallel Assembly Lines. European Journal of Scientific Research, ISSN 1450216X Vol.31 No.4, pp.616-631© EuroJournals Publishing, Inc. 2009, http://www.eurojournals.com/ejsr.htm • Falkenauer, E. and Delchambre, A. (1992) `A Genetic Algorithm for Bin Packing and Line Balancing', Proceedings of the 1992 IEEE International Conference on Robotics and Automation, May 10-15, 1992, Nice, France. IEEE Computer Society Press, Los Alamitos, CA. Pp 1186-1192 • Lee Quarterman, (2000). How to balance a manufacturing work cell. IE Solution Conference- May 21-23, 2000.IIE. Pp 1-5 • Lorenz Hans-Walter & Scholl Armin, (2006). Assembly line balancing: Which model to use when?, ISSN 1611-1311, Wirtschaftswissenschaftliche Fakultät Friedrich-Schiller-Universität Jena Carl-Zeiß-Str. 3, 07743 Jena,
[email protected],
[email protected], www.wiwi.unijena.de • Nuchsara Kriengkorakot, Nalin Pianthong, (2007). Review article on The Assembly Line Balancing Problem, KKU Engineering Journal, Vol 34 No.2, PP 133-140. • Rekiek Brahim, Delchambre A., A book on Assembly line design, the Balancing of Mixed-Model Hybrid Assembly Lines with Genetic Algorithms, Springer-Verlag London Ltd.,2006 • Seamus McGovern & Surendra M. Gupta, A book on The Disassembly line: Balancing and Modeling, McGraw-Hill, 2010 69
• Vora C.S., Solanki M.S., Jhala P.B., Godiwala Pavan & Paul Verghese (2002), IT based sweing room data for improved performance of SME’s in garment sector, Paper Presented to 43RD joint technical conference,2-3 March, PP.1-6 • International Labor Organization, 2001, “Productivity competitiveness & Job Quality” • Lab View Tutorial/Manual • http://www.linebalance.com • http://www.askaboutvalidation.com/production-line-balancing/ • http://classof1.com/homework_answers/operations_management/assembly_line _balancing/ • http://www.transtutors.com/homeworkhelp/Industrial+Management/Line+Balancing/line-balancing-problem.aspx • http://www.stageindia.net/proman.htm , Eco Tech Pvt. Ltd. Proman Apparel Software 21st March 2007 • http://www.protech-ie.com/flb.htm • http://www.asco.com/linebalncing.htm ,Applied Computer Services Inc Timer Pro Professional, 21st March 2007 • http://en.wikipedia.org/wiki/LabVIEW • http://www.scribd.com/doc/7699063/Introduction-of-Line-Balancing • http://www.cmai.in/news/apparelnews_view_index.asp?articleID=58
• http://www.redeemingtime.com/Piston_Study.htm
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13) ANNEXURE: Annexure-13.1 HARDWRE AND SOFTWARE REQUIRED: Computer has the hardware and software listed below: MINIMUM: 9 Microsoft Window (9X/NT/2000/Me/XP/Vista) 9 A personal computer with 486DX/2 or higher CPU (Pentium- Class recommended) 9 A hard disk with approximate 20 MB of available space 9 At least 32MB of RAM memory (more recommended for mprove performance) 9 A Mouse or other pointing device & Printer 9 A CD-ROM drive (for program installation) RECOMMENDED 9 500MHz Intel Pentium-III processor or greater 9 128 MB RAM or greater 9 100+ MB Hard Disk space forsaving data & records 9 Microsoft Window (9X/NT/2000/Me/XP/Vista) 9 A mouse or other pointing device & printer 9 A CD-ROM drive (for program installation) Flexible Line Balancing uses the COMSOAL (Computer Method of Sequencing Operations for an Assembly Line) procedure to assign work elements to stations. In this heuristic method, hundreds or thousands of calculations are quickly performed on the computer until the absolute best solution is found. In a few seconds, you can solve a complex work allocation problem on a progressive assembly line of virtually any number of workstations. 71
Following is a list of some of Flexible Line Balancing's many features: •
The best (most labor efficient) solution is always found.
•
As elemental task data is entered into the program, when the program solves the problem, text descriptions of elements are grouped by station, corresponding to the precedence breakdown.
•
When the program completes a solution, a presentation shows elements assigned to each workstation, and the total standard time at each station compared to SAM.
•
Every manual change made to the computer solution automatically recalculates line efficiency.
•
Line Balancing Engine handles any kind of constraint. Work elements can be independent, preceding or following, done as part of other operations, done off-line, done in a specific work group, or other conditions.
•
Standard times may be any consistent time unit - seconds, minutes, hours
•
Save individual work elements ("Standard Elemental Tasks") or entire processes, then import them into new line balancing problems. Build new assembly processes from a "library" of stored work elements.
•
Full data editing capabilities, including cut, paste, insert, append, and delete. Edit individual work elements on the Standard Elemental Task screen, or entire processes on the Process screen.
•
Zoom and Print Preview features on every program screen. View and print elemental task summaries.
•
POP UP alerts at every stage make the user more comfortable with entering data & confirm the accuracy by avoiding wrong data entry or blank column entry. Thus the software makes the planner, supervisor & management life easy and gives them more time to think on other problems instead of line balancing.
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Annexure-13.2
SOFTWARE AVAILABLE FOR LINE BALANCING The following is the list of commonly used software for line balancing: 9 Flexible Line Balancing is a joint development of LG Electronics Inc., a diverse international manufacturer, and Production Technology Engineering and Management Services as program distributer. 9 Computer software for line balancing with consideration of lean production criteria, Turkish University. 9 Tanya Geometrik, a computer graphics software development company offering CAD solution to the apparel industry, has developed software for line balancing called Linebalance.com.
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