A Decision Support System to Determine the Ideal Number of Workers Using a Line Balancing Method

Abstract

This paper presents an analysis of a typical assembly line problem which examines how to balance a manual packing line of a local company engaged in manufacturing snack foods. The subject assembly line consists of various manual activities thus seeing the need to set up standard time in order to control excess labor cost and to avoid forcing the worker to perform beyond his or her normal capacity. The work aims to initially establish time standards for activities involved in every workstation through time study. The appropriate time study technique for the subject process line will be briefly discussed on the study. As a result, line balancing approach will be utilized to determine the optimal number of manpower requirement per workstation. Given this method, the study seeks to eliminate build-up of work-in-process between activities, minimize the deviation of utilization of workstations, maximize the capacity of the line and minimize the labor-hour expended per unit of product. The desired outcome of the study is to develop a configuration that will serve as a decision support system for the person in charge to estimate the ideal number of crew to be positioned per workstation. Additionally, the benefits of "walking-worker" will be introduced over a conventional fixed worker in an assembly line. The work will also provide the company an initial systematic procedure for setting up time standards and a performance control system for other product lines.