Cycle time reduction in assembly line through layout improvement, ergonomics analysis and lean principles

Line Balancing is leveling the workload across all processes in a line or value stream to remove bottlenecks and excess capacity. The objective of assembly line balancing is to assign processes and tasks to the individual work station such that the total time required at each workstation is approximately same and equal to or below the Takt time. This paper mainly focuses on improving overall efficiency of multi-model assembly line by identifying and eliminating non-value added activities, making alterations in work stations, layout improvements to eliminate operator movements, and reduction of work content through postural analysis of operators using REBA (Rapid Entire Body Assessment) analysis.