Once the individual process steps and sub-processes of the assembly have been defined, they are divided up into the assembly stations. In addition to the cycle time for each individual process, the restrictions from the assembly sequence, the cycle time of the system, i.e. the customer cycle, is crucial.
When dividing up the stations, the aim is to level out cycle time fluctuations across the line, the so-called "line balancing". Nevertheless, station contents can arise that do not completely fill the cycle time or exceed it. An optimally planned system can help to reduce the cycle balancing time and to make better use of the employees or machines. The efficiency of the assembly system is increased by line balancing.
For complex planning projects that include many component variants and/or production sequences, detailed balancing with manually operated calculation tools alone is no longer possible. In this case, it is recommended to consult experts in the field of IT-supported planning and simulation to evaluate the cycle time and optimize line utilization.
There are various approaches to adjusting the cycle times of the individual stations in an assembly system and thus achieving the specified cycle time or reducing the cycle time. In the case of manual assembly stations, a positive effect on production time can often be achieved simply by redesigning the workplace and optimizing the ergonomics at the workplace. By adjusting the assembly sequence, waiting times can be used for preparation purposes. And last but not least, the selected assembly technology and the design of the assembly aids have an influence on the time required.
What potential can be used for the respective assembly system is very individual and can be determined by analyzing the workplaces and using time recording methods, so-called Methods of Time Measurement (MTM analyses). A digital analysis of the workplaces and the ergonomics at the workplace is also possible and offers the advantage of directly simulating the result and effect of changes and adjustments.
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