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Procedia CIRP 40 (2016) 437 – 442
13th Global Conference on Sustainable Manufacturing - Decoupling Growth from Resource Use
Abstract
Line balancing is required in most of production lines, but bottleneck point often happens. As the results, many wastes would be occurred.
There are many methods or tools to balance the line as well as eliminate wastes. In this paper, a lean line balancing would be studied as a
simple tool, but impressive results would be brought. It would be applied in improvement of an electronics assembly line. Analysis on the
current line would be done to figure out wastes and conceive the ideas to solve them. The quality of production line would be shown on the
productivity, line balancing index, and effectiveness on resources. Actually, many benefits for the studied electronics assembly line were
brought, which could be considered as a force to apply lean line balancing tool for other production lines.
© 2016 The Authors. Published by Elsevier
Elsevier B.V.
B.V. This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
Keywords: Lean line balancing; Electronics assembly line; Line balancing; Takt time; Lean manufacturing
2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
doi:10.1016/j.procir.2016.01.089
438 Nguyen Thi Lam et al. / Procedia CIRP 40 (2016) 437 – 442
Resource
Resource No. Operation description
No. Operation description Operator Machine
Operator Machine Locate the standard
Locate the motherboard in the 1 form on the X
1 fixture machine and close X motherboard.
machine cover. 2 Check the item X
Input the data and report the Check the appearance
2 X 3 X
result. quality.
3 Open machine cover X Check the lower CLD
If the report of the result is 4 X
pad plate
fail, the motherboard is moved Input the barcode in the
4 X 5 X
to the debug workstation. A MES system.
red sticker note is pasted on it. If test result is fail,
Transport the motherboard to - Paste an error note on
5 the FVT workstation if it is X the motherboard
passed. - The error information
is recorded in the MES
6 X
system.
The Function Verification Test-FVT workstation - The error
has one operator controlling independent fixture motherboard is
machines. Each machine can only test one transported to the
rework station.
motherboard at a time. The operator has to open the If the test result is good,
fixture machine, locate the motherboard in the 7
the motherboard is
X
machine, as well as wait the machine testing transported to the Pack
out workplace.
motherboard inputted program. If the machine reports
the green light, the motherboard is passed. If it reports
The Pack out workstation has one operator packing
the red light, the motherboard is fail. It would be
the motherboard. The operator activities includes
transported to the next suitable workstation. The FVT
picking up the motherboard, collecting the ESD cover,
process is summarized in Table 2.
putting the motherboard into the ESD cover, and
Table 2. Operation process at the FVT workstation packing as well as locating it in the box. Each box can
Name of Workstation: FVT workstation handle 84 packed motherboards. The pack out
Product ID: Electronics motherboard workstation process is summarized in Table 4.
Table 4. Operation process at the Packout workstation
After the operation process was analyzed, the operator Table 7. Operator value-added and non-value-added activities at the FNI
value-added and/or non-value-added activities were workstation
identified for every workstation. At each workstation, 1pieces
Name of Workstation: FNI workstation
all operations processing cycle time were collected. /batch
Besides, operations would be classified into value- Electronics Cycle
Product ID:
motherboard time
added or waste activity. They are summarized as Activities (second)
following Tables. No. Operation description Value-
Waste
added
Table 5. Operator value-added and non-value-added activities at the ILP Use two hand move the 4.00
workstation tested motherboard to
Name of ILP-Inline 4pieces 1pieces the pack out
1 X
Workstation: Loading Program /batch /batch workstation and pick up
Electronics Cycle Cycle another one from the
Product ID: buffer tray to test.
motherboard time time
Activities (second) (second) Check the appearance 13.50
Operation 2 X
No. quality.
Value-
description Waste Scan the barcode to the 3.00
added 3 X
Locate the 18.00 4.50 MES system
motherboard in Cycle time 20.50
the fixture
1 X
machine and
close machine Table 8. Operator value-added and nonvalue-added activities at the
cover. Packout workstation
2 Scan offline X 13.00 3.25 1pieces
Observing the 23.00 5.75 Name of Workstation: Packout workstation
/batch
inputting data Electronics Cycle
3 process and X Product ID:
motherboard time
reporting the (second)
Activities
result. Operation
No. Value-
Open machine 14.00 3.50 description Waste
added
cover and then
Pick up the 3.00
move the
motherboard and scan
4 motherboard to X 1 X
information (barcode)
the next
in the MES system.
suitable
workstation Fix the motherboard in 3.00
2 the cover P/N X
Exchange tray 0.70
JBAG0018 - NE
trolley and
5 X 3 Pack the mother board X 4.60
exchange tray
to tray Fix the packed 3.00
Cycle time 68.00 17.70 4 motherboard in the X
box.
Cycle time 13.60
Table 6. Operator value-added and non-value-added activities at the FVT
workstation
The distribution of cycle time at each workstation
Name of FVT-Function 4pieces 1pieces was shown on Fig 4, in which the waste time is mainly
Workstation: Verification Test /batch /batch occurred at the ILP and FVT workstations. The
Electronics Cycle Cycle
Product ID:
motherboard time time percentage of the waste time of the line around
Operation
Activities (second) (second) 12.18%.
No.
description
Value-
Waste Actually, there are many factors affecting to the line
added
Pull the 20.56 5.14
productivity, which relate to manufacturing
testing environment, human factor, suddenly activities, and
machine machine broken down. The added coefficient was
frame; analyzed [7] and identified as summary in Table 9.
Locate the
motherboard
1 in it; Push X
the testing
machine
frame; And
transport the
tray to the
FNI buffer.
2 Scan offline X 38.00 9.50
Observe the 10.68 2.67
inputting
3 X
data program
process
Cycle time 69.24 17.31
Nguyen Thi Lam et al. / Procedia CIRP 40 (2016) 437 – 442 441
Waste time Table 10. Summary of the cycle time at each workstation
Therefore, 5. Conclusions
9 Line balancing ratio equals ሺʹ͵Ǥͻ ʹͲǤͷ
ͳ͵ǤሻȀሺ͵ܺʹ͵ǤͻሻܺͳͲͲΨ = 80.89%; The quality of the electronics assembly line was
9 Line balancing efficiency equals ሺʹ͵Ǥͻ ʹͲǤͷ enhanced in terms of line balancing index, overall labor
ͳ͵ǤሻȀሺ͵ܺʹͺǤͲͺሻܺͳͲͲΨ = 68.85%; effectiveness, productivity and elimination of wastes.
9 The percentage of the waste time of the line is Although human resource was decreased 25%, the customer
reduced from 12.8% to 10.3%; demand could meet. This research shows that there are
However, the operator working time at the ILP-FVT many wastes which could be eliminated with the simple
workstation is still around 85% (23.90/28.10) cycle time. lean tools. It is not very complicate but it would bring
Three alternatives were considered: The current line, essential benefits.
ILP-Pack out combination, and ILP-FVT combination After the line is balanced, standardization of works
alternative. Many criteria were used to evaluate them as should be done. The guideline should be developed in detail
shown in the Table 12. The suggested alternatives were for training and assuring the quality of jobs. Other lean
better than the current one in terms of line balancing index tools such as 5S, Kaizen, or TPM should be studied, which
and unit per hour per person one. In addition, twenty five could support setting up the lean environment for the
percent of human resource were reduced; and overall labor company.
effectiveness index is increased in both suggested
alternatives. Currently, the option 2 has been applied due to
without investment more. However, the ILP-FVT operator References
worked most full time. It is not good for a long time.
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- LBI: Line Balancing Index (%)
design”, McGraw – Hill, 1999.
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