Simulation-based assembly line balancing and manpower allocation in a cellular manufacturing system

Abstract

A well-balanced manufacturing system is key for ensuring a smooth production flow and the most efficient use of manpower and equipment This study aims to improve the cellular manufacturing system’s assembly line balance and achieve optimal manpower utilisation at the bottleneck process. The methodology for evaluating the equipment and manpower performance for the manufacturing system was WITNESS simulation modelling and Maynard Operational Sequence Technique. Based on the simulation results, the test process was the bottleneck and the existing production was struggling to meet the customer demand due to machine shortages. Overproduction waste and a high work in progress inventory were discovered due to an imbalance in the Die Clip Bond and Trim and Mark processes causing overproduction wastes and very high work in progress inventory. A more balanced production line was observed after changes to the Die Clip Bond, Test and Mark and Test machine configurations. Inventory wastes at the Die Clip Bond and Trim and Mark were reduced by 52% and 73%, respectively. The test area’s manpower was kept at two, but two machines were added to increase the machine capacity and meet expected increases in customer demand. The top three major contributors to the high manpower utilisation of 98% during stagger break were identified and proposed to be the focus for productivity improvement projects. Overall, simulation and MOST work study technique have proven to be effective tools for evaluating the performance of cellular manufacturing system.