Manufacturing Systems Analysis
and Management
Load Balancing
Maruti Suzuki
Vikas Kumar Saw
Vinay Bansod
Vinod Kumar Verma
Vishal Bansal
Vishnu M Das
2301189
2301190
2301191
2301192
2301193
Introduction
• An assembly line is a flow-oriented system which caters to the industrial production of making standardized parts.
• Line restructuring or rearranging the work sequence can be effective to improve the throughput of the assembly
lines.
• Allocation of the workloads as evenly as possible within the workstations is a common practice among the
manufacturers.
• It brings about a sense of equity between the workers and also helps in maximizing the outputs
• Production departments are highly satisfied with the assembly line if the line can achieve higher level of line
efficiency.
• The higher the level of efficiency indicates that the line implemented by the company is the best line for the
production process and also capable of producing higher outputs in the specific given time
Line Efficiency (%) =
𝑇𝑜𝑡𝑎𝑙 𝑇𝑖𝑚𝑒 𝑜𝑓 𝐴𝑐𝑡𝑖𝑣𝑖𝑡𝑖𝑒𝑠
∗ 100
𝑁𝑜. 𝑜𝑓 𝑊𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠 ∗ 𝑇𝑎𝑘𝑡 𝑇𝑖𝑚𝑒
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐿𝑜𝑎𝑑 % =
𝑆𝑡𝑎𝑡𝑖𝑜𝑛 𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒
∗ 100
𝑇𝑎𝑘𝑡 𝑇𝑖𝑚𝑒
Problem Definition
Door Line Station wise Loading
Station No.
1
2
3
4
5
6
7
8
9
10
Station Cycle time Takt Time
103.38
157
119.7
157
122.51
157
133.26
157
103.14
157
114.44
157
134.2
157
118.7
157
115.42
157
109.5
157
Station Loading (%)
65.85
76.24
78.03
84.88
65.69
72.89
85.48
75.61
73.52
69.75
Door Line Loading (Before)
Improving Resource Allocation
• The set of activities on workstations are observed and analyzed.
• Table shows the station identified and the activities performed on the stations which need to be
altered. The activities that are identified are marked with red coloring.
Activity description Activity time
Assemble run
channel with
49.8
division bar
Station 1
1
Station 2
2
Front door glass
assemble
36.88
3
Rear window glass
sub-assembly
7.39
4
Station 5
5
6
Get rear
subassembled
window glass and
check the glass
Place glass in rear
RH door
Check and mark
rear door check link
bolts
3.89
10.29
6.19
Station time
Takt time
114.44
157
Definition of Load Balancing
Load balancing in manufacturing refers to evenly distributing tasks,
workloads, or production processes across available resources,
such as machines, workers, or workstations a way that prevents any
one workstation or machine from becoming a bottleneck that slows
down the entire production process.
10
2
6
2,4
6
4,4
4
2
0
8
8
4,3
2,5
1,8
8
3,5
0
2
4,4
1,8
4
2
0
0
2,4
4,3
8
3,5
2,5
0
Category 1
Category 2
Series 1
Category 3
Series 2
Category 4
Category 1
Category 2
Series 1
Category 3
Series 2
Category 4
Series 3
Load Balancing
Work Station 1
Work Station 2
Previous CT
103.38
119.7
New CT
153.18
156.58
Door Line Station wise Loading (After)
Station No.
1
2
3
4
5
6
7
8
9
10
Station Cycle time
153.18
156.58
122.51
133.26
130.9
0
134.2
118.7
115.42
109.5
Takt Time
157
157
157
157
157
157
157
157
157
157
Station Loading (%)
97.57
99.73
78.03
84.88
83.38
0.00
85.48
75.61
73.52
69.75
Door Line Loading (After)
Results
Parameters
Number Of Workstations
Line Efficiency
Manpower for one shift
Yearly savings for the company
Before
After
20
18
74.79
83.10
40
36
16, 80,000
Elimination of two workstations
Workload shifting to under loaded workstations lead to elimination of workstation-6 and its mirrored
station on other side of the conveyor. Therefore, the total number of workstations was reduced
from 20 to 18.
Reduction in manpower
Elimination of two workstations on either side of the conveyor led to elimination of 4 operators (2
operators each for 1 workstation) in a single shift.
Cost savings
Operator costs for one workstation in two shifts per day
Yearly savings = 35,000x2x2x12= Rs.16, 80,000
Thank You