Reduction of Manufacturing Cycle Time using Line Balancing – A Case Study

This paper deals with the reduction in manufacturing cycle time of a product using line balancing algorithm. The case study was undertaken in an industry that manufactures air-oil separators for compressors. Current state value stream map was drawn to identify the problem areas. The scope of study was limited to the bottle neck stations. The bottle neck stations are dedicated to the production of the chosen product and there is no mix of products in these stations. Time study was performed to ascertain the adherence of the current process to the takt time. Various tools such as fish bone diagram and Pareto chart were used in the analysis to identify major reasons for non-adherence to takt time. The line was balanced using COMSOAL algorithm to eliminate the involvement of worker and to meet the takt time. The cycle time in the bottle neck stationwas reduced by 5% and the involvement of a worker was eliminated.