Production Line Efficiency Improvement Using the Line Balancing Method on the 3W Frame Welding Line at PT X
DOI:
https://doi.org/10.35194/jmtsi.v10i2.6581Keywords:
Line BalancingAbstract
Manufacturing assembly lines frequently face operational inefficiencies due to unbalanced workloads and discrepancies between legacy Work Instructions (WI) and actual shop-floor cycle times. At PT X, the 3W Frame Welding Line exhibited a low initial Line Efficiency (LE) of 54,83% and a 3,290-second time data gap between documented procedures and actual operations, resulting in severe line imbalances and restricted output. This study aims to eliminate the time data discrepancy, redesign the workload allocation across workstations within the target takt time, and evaluate the resulting operational and financial improvements. The methodology integrates the Eight Steps problem-solving framework with the Ranked Positional Weight (RPW) heuristic method and Lean visualization tools, including Standardized Work Combination Tables (SWCT), Standardized Work Charts (SWC), and Yamazumi Charts based on stopwatch time studies. The results show that standardization successfully eliminated the 3,290-second data gap with 100% document accuracy. Following line balancing across three workstations, LE increased significantly from 54,83% to 94.67%, Balance Delay (BD) dropped from 45.17% to 5.33%, and daily production capacity doubled from 10 to 20 units without overtime. This study concludes that combining the RPW method with visual standardized work effectively resolves shop-floor bottlenecks and data asynchrony, delivering a projected Net Quality Income (NQI) of IDR 4,596,249,600 per year.
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