Line balancing using lean manufacturing tools at balloon packaging department

Abd Aziz, Syazxerlin (2017) Line balancing using lean manufacturing tools at balloon packaging department. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The aim of the study is to rebalance the work load of each operator at the manual packaging department. The B100 balloon and packaging type A is chosen as the subject of this study. Every packaging line will have an allocated time to finished the packaging product, but this packaging line have a problem to finish it within the 11 hours given. The actual time the packaging line took to finish it is aproximately 13.5 hours to meet 13000 packs of customer demand. The objective is to study and analyze the potential wastes at the manual packaging line. Moreover, to propose an effective and efficient solution or action regarding the problem issued; Methodology used in preliminary stage are observation, video capturing and time recording, interview session and site visit to have a clearly view about the problem highlighted. The time study, ishikawa diagam, pareto chart, takt time and line balancing tools are used to analyze the current situation. Line balancing ratio, line arrangement efficiency and expected output had been obtained The sub activities of each operation involved had been declared either value added or non-value added activities. Through this identification, fragment task had been obtained in order to construct yamazumi chart. The work station layout redesign is based on the number of operator required. Second solution is by using Kaizen tool (2 Ways Moveable Container). This tool is functioned as a material handling tool between two work stations. The operator need to push or pull the moveable container in order to eliminate travel distance. The takt time of packaging process is 3.05 seconds, line balancing ratio is increased up to 90.96%, line arrangement efficiency is about 86.23% and expected output is 13655 packs, exceed the customer demand. Total saving cost of packaging line is RM91.88 and 19.50% saved from its original labor cost within 11 hours.

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