Lean Manufacturing Design of a Two-Sided Assembly Line Balancing Problem Work Cell

Kamarudin Abu Bakar, Mohd Fazli Mohd. Sam, M.I. Qureshi

Research output: Chapter in Book/Report/Conference proceedingConference contribution


Line balancing is a very important concept in Lean manufacturing. It ensures that operators are not idling but instead work effectively for continuous productivity particularly in two-sided assembly lines. In the study conducted at a glove making facility, cuffing task (of 210 mm length) at three workstations/side has an average lower speed of 23 pieces/min. Effective cycle time of 0.4 min calculated using heuristic method was well applied for line balancing. However, the idea of additional workstation was not sustainable to meet new customers’ demand. Alternatively, a practical integrated approach was introduced as the solution. Load balancing of higher than 68 packs/min that streamed down the work cell could be enhanced by stopper jigs installation and operators’ positions rotation (and repositioning). As a result, the value stream levelling (Mura) has shown improvement in the output by 27–30 pieces/min and 70–72 packs/min at maintainable fixed costs. The findings were evidence that the techniques used could reduce operational wastes (Muda) namely transport, stocks, movement, and waiting. Just-In-Time (JIT) concept as depicted by smooth production flow also helped to accommodate the cells production being carried out at constant and predictable rate. Hence, the process-based practice could effectively encourage a flexible Lean practice.

Original languageEnglish
Title of host publicationIntelligent Manufacturing and Mechatronics
Subtitle of host publicationProceedings of SympoSIMM 2021
Number of pages11
ISBN (Print)9789811689536
Publication statusPublished - 25 Jan 2022
Event4th Symposium on Intelligent Manufacturing and Mechatronics - Symposium on Intelligent Manufacturing and Mechatronics, Melaka, Malaysia
Duration: 8 Nov 20218 Nov 2021

Publication series

NameLecture Notes in Mechanical Engineering


Conference4th Symposium on Intelligent Manufacturing and Mechatronics
Abbreviated titleSIMM 2021
Internet address

Bibliographical note

Funding Information:
Acknowledgements. The authors would like to thank the Sustainable IT Economics Research Group (SuITE) and the Universiti Teknikal Malaysia Melaka (UTeM) for all the support given for the research work.

Publisher Copyright:
© 2022, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.


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