Application of Two Sided Assembly Line Balancing for Lean operations - A Case Study

The present study aims to solve the Two-Sided Assembly Line Balancing Problem (TLBP) by spread sheet model employing Enumerative Heuristic Algorithm (EHA). The problem source was identified based on the need for TI cycles of India to manufacture 24000cycles/month in exports bay. The existing assembly line was found infeasible from time study. A multi-objective optimization of a two-sided assembly line is considered, which is minimising number of workstations thereby reduce number of workers, minimise idle time, uniform distribution of load and matching supply with demand. Takt time calculations were made after thorough investigation of existing assembly line and time study performed elucidates each tasks standard processing time, direction and precedence relation. A two sided assembly line processing layout was eventually developed from an optimal assignment foraged from a solution space by Pareto analysis. The results of final assembly line for the cycle time of 57.6 sec indicates line efficiency of 85.25 %, smoothness index 46.05 and increased production rate of 500 units/shift with reduction in number of workstations.