Line Balancing Improvement in the Welding Section of a Car Assembling Plant

Abstract. This paper presents a case study on a line balancing problem in a car assembling plant. This study was aimed at providing alternatives in reducing current problems at the H-N welding line of the body assembling section in the plant. Investigation was conducted to identify causes for bottlenecks that resulted in low productivity level and high resource wastage. Using the results of unstructured interviews, time study data and observations on the process, the problem was analysed and the main causes identified were unbalanced line and poor material handling system. To improve the current situation, alternatives were generated using line balance technique. QUEST, which is a 3D digital factory simulation software, was used in the analysis of the alternatives. The process was modelled using QUEST and simulation was conducted on the current system and also several possible alternatives. The results of the simulation studies were analysed and evaluated before the best alternative is selected and proposed. The paper culminates with a proposed solution to improve line balancing at the selected welding operations in the company.