Increase production capacity by performing assembly line balancing study in food and beverages manufacturing

Manap, Nur Ain Najwa (2023) Increase production capacity by performing assembly line balancing study in food and beverages manufacturing. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The manufacturing industry is experiencing rapid development and has progressed for the future. Any progress definitely comes with problems that need to be solved. A common problem faced by the industry is the imbalance of a bottleneck at each workstation. It is an issue that is underestimated by all industries including Food and Beverage Industries. A method such as Assembly Line Balancing (ALB) is one of the solutions to the problem. Typically, ALB is not used in the most efficient way possible. This is because the ALB method is still lacking in terms of infrastructure and technology to detect problems at workstations. Therefore, it will affect Work-In-Progress (WIP) which is considered an incomplete product. The objective of the study began by identifying the causes influencing the imbalance in the Assembly Line (AL) at the workstation. Next, the investigated causes help identify appropriate techniques for resolving task distribution imbalances at workstations. So, this technique will contribute ideas with respect to actions for the improvement of task time and WIP. The framework for this study is been planned and arranged based on a literature study related to ALB. The qualitative and quantitative approaches such as data collection are essential to complete the study. Interviews, image capture, and the arrangement of the form data for calculation and formulation were all used in the data collection process. An equation from cycle time to line efficiency is used based on the structure of ALB components. The result of the calculation is to find out which station is the most unbalanced. Then, Cause and Effect diagrams are been used to identify the incidence of loss factors and causes meanwhile the Why-Why Analysis used to make suggestions and ideas for improvement. Then, the study can be applied to the Food and Beverage Industry. Thus, the thesis that contains research about ALB will be beneficial and useful, especially to the manufacturing company that aims to increase production productivity.

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