Line balance analyses for system assembly lines in an electronic plant

This research analysed and optimised the assembly line balance of notebook computer system production lines in a major computer plant. The research developed a mathematical model for balancing assembly lines of a specific notebook computer system. Precedence relationship charts were created to enforce the required sequences and ILOG CPLEX software was used to obtain the optimal solution of the task assignments to the workstations. The new task assignments were simulated to verify the improvement recommendations and predict the potential benefits.The estimated improvements include: (1) 5.9% increase in average daily production; (2) 29% decrease in average daily WIP; (3) 67.9% reduction in cycle time; (4) 16.7% reduction in operator headcount over the whole system assembly area. The contributions of this research include: (1) Establishing line balancing mathematical model suitable for notebook computer factories; (2) Optimising the system assembly lines for the subject company; (3) Transferring the line balance modelling and optimisation techniques for company use.