Implementation and Line Balancing of Assembly Line of ABS

Motor for Improvement of Assembly Productivity

Brain Korea 21 Logistics Team
Industrial Engineering / Pusan National University


Author :
S.T. Pyo(12pt, bold)
(Assembly Automation Lab., Industrial Engineering, Pusan National University)

Thesis supervisor :
Prof. H.S. Mok(12pt, bold)
(Assembly Automation Lab., Industrial Engineering, Pusan National University)
2 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
Abstract
This paper proposes a implementation procedure of flexible assembly line of ABS motor which
is composed of four subassemblies, yoke, grommet, housing, armature. The characteristics of
ABS motor and assembly process are analyzed, and then the automation possibility of each unit
process is decided to decrease an assembly time and cost. The assembly machines and facilities
are selected for automatic assembly, and then the layout of the selected facilities is performed.
Task allocation of each worker is achieved by assembly line balancing to increase an assembly
productivity and efficiency.





BK21LogisticsTeam, July2000 3
Contents

Abstract . . . . . 2
List of frequently used symbols . ..4
1 Introduction. . 5
2 Analysis of assembly object and process . .6
2.1 Analysis of part and subassembly of ABS motor. 6
2.2 Analysis of assembly process of ABS motor. . . 6
3 Implementation of assembly line of ABS motor. . 8
3.1 Determination of automation possibility of assembly process automation. .8
3.2 Determination of assembly equipment of assembly process...9
3.3 Layout of assembly machinery equipment.....11
3.4 Work assignment and line balancing......12
4 Conclusion . . 16
5 Reference . . . . . 17




4 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
List of frequently used symbols

K = Number of works
CT = Cycle time
T
i
= Working hours of each worker
T
max
= Maximum working hours of each worker


BK21LogisticsTeam, July2000 5
1 Introduction
Automatic assembly process can produce a product quality with consistently high reliability
compared with manual assembly. But, to implement an automatic assembly line, there are some
problems.
First, assembly process has technical and economical risk than other processes due to its
accumulative errors. Second, it should be implemented a different assembly system according to
products. Therefore, when it has to produce fixed equipment and has limited investment cost
and feeding area, it needs a flexible assembly system that includes a manual assembly for
specific assembly process.
The research of assembly line implementation has been focused on invest analysis which
determines the best investment cost with limited capital and line balancing for the maximum
efficiency of assembly line. Therefore it is needed flexible assembly system by mixing of
automatic assembly and manual assembly.
Study for implementation of assembly line is focused on assembly line balancing, which is
maximizing investment analysis and efficiency of assembly line. And it has been also studied a
DFA(Design for Assembly) for ease of assembly and assembly automation, devices for parts
transporting, arrangement, feeding and joining, machines and equipments of arrangement and
evaluation for efficient usage .
In this research, we suggest an implementation procedure of flexible assembly line of ABS
motor, and a method of assembly line balancing which can increase an assembly productivity
and efficiency.
First, new assembly procedure is determined by characteristics analysis of ABS motor and
analysis of finished assembly line. Second, determination of automation possibility for each of
assembly process by characteristics of ABS motor and assembly process, volume of products
and cycle time, etc. Third, the assembly process determines assembly devices. Finally, machine
layout and work allocation are determined by object product volume in cycle time.
6 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
2 Analysis of assembly object and process
2.1 Analysis of part and subassembly of ABS motor
There are 4 subassemblies of ABS motor; Yoke subassembly, Housing subassembly, Armature
subassembly, Grommet subassembly. Yoke subassembly is composed of 9 parts and 5 kinds of
parts; Yoke, magnet, magnet holder, bearing, bolt. Housing is made up of 4 parts; housing,
bearing, bolt. Grommet subassembly has 24 parts; brush holder, brush spring, cable, etc. And
armature subassembly is composed of 5 parts; shaft, commy, core, o-ring etc.










Fig. 1 Subassemblies of ABS motor
Fig.1 shows 4 subassemblies of automobile ABS motor; yoke housing, armature and grommet.
2.2 Analysis of assembly process of ABS motor
Assembly processes of ABS motor are made up of a number of 34 unit process; armature
cleaning, o-ring insertion, grommet silicon application, housing and grommet insertion, brush
insertion, spring insertion to brush holder, rotor bearing insertion, silicon application and yoke
assembly, and packing, etc.
They can be combined into of 15 processes like Table 1 grease application, magnet holder
assembly, holder insertion to yoke pig tail control, air supply, bolting of yoke, magnetization of
magnet and airtight test, etc. For instance, grease application is that gets a grease or o-ring by
injector. The important control factors of this process are number of o-ring, amount of grease
application and check whether the grease application is done to all o-ring uniformly.


Yoke
Subassembly
Armature
Subassembly
Grommet
Subassembly
Housing
Subassembly
BK21LogisticsTeam, July2000 7
Table 1. Assembly process ABS motor









Fig. 2 shows operation sketch and main control items of grease application, air supply, o-ring
insertion process of operation number 1.









Fig. 2 Sketch and control factors of no.1 work
Important control factors of grease application are number of o-ring, amount of grease
application, whether the grease application is done all o-ring uniformly and location of o-ring,
etc. Important control factors of air supply and o-ring insertion are exterior view of commy and
shaft, whether the grease application is done to o-ring and location of o-ring, etc.




No. Assembly process Time
1
Grease application, Air supply,
O-ring insertion
15
2 Magnet holder assembly 12
3 Holder insertion to yoke 8
4 Bearing insertion to yoke 8
5 Armature and Bearing insertion 15
6 Pig tail control, Air supply 10
7 Silicone application, yoke insertion 14
8 Grommet insertion 28
9 Bolting of brush holder 10
10 Bolting of yoke 10
11 Spring insertion to brush holder 34
12 Magnetization of magnet 15
13 Aging ~ Load test 16
14 Airtight test 15
15 Sticker sticking, rust preventing, packing 16


Injector
Grease
Vinyl-bag
O-ring
(100ea)
O-ring

Armature
Jig
Grease application Air supply, O-ring insertion
Important control factors
Exterior view of Commy
Exterior view of Shaft
Whether the grease
application is done to O-ring
Location of O-ring
Number of O-ring
Amount of grease application
Whether the grease
application is done to all
O-ring uniformly
Location of O-ring
8 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
Fig. 3 Determination of automatic and manual assembly
3 Implementation of assembly line of ABS motor
3.1 Determination of Automation possibility of assembly process
automation
According to geometrical characteristics of products and degree of complexity of assembly
process, it can be determined whether the assembly processes can be automated or not(Fig.3).
Because manual assembly can be performed very easily, we don t have to waste unnecessary
investment cost, if it is very difficult process to perform by automatic assembly.
There are some influencing factors to determine automatic or manual assembly like a
production volume, cycle time and investment cost, etc. Manual assembly is performed, if part
characteristics are weak in transporting, arrangement, feeding, joining area. In this research, we
analyze assembly process and object that is used in the process to determine automatic or
manual assembly. If a part is difficult to be assembled automatically at the four areas,
transporting, arrangement, feeding, joining, it is assembled manually.











In this research, automatic assembly and manual assembly are determined by considering of
assembly process and part characteristic. In the aspect of part characteristic, it distinguishes the
weak parts from others that satisfy with precondition of transporting, arrangement, feeding and
joining for automatic assembly. Therefore the part is determined manual assembly. The others
that satisfy with preconditions of process are decided automation probability in terms of
assembly possibility. The processes that don t satisfy with assembly possibility are performed
by manual assembly. The processes that satisfy with assembly possibility determine equipment
of automatic assembly. And the processes that are determined by manual assembly are
determined the method of transporting, arrangement, feeding and joining.
Table. 2 shows that example of the grease application process that applies for number of 4 area;
transporting, arrangement, feeding, joining. Transporting area can be divided into T1(Possible
continuous transporting), T2(Available transporting), T3(No tangling in transporting) and
Determination factors of product
l Geometric characteristics
l Design for assembly
l Market life
Area of consideration
l Transporting area
l Arrangement area
l Feeding area
l Joining area
Influencing factors
l Production volume
l Tact time
l Investment cost
l Utilization of labor
Determination factors of process
l Degree of complex of process
l Assembly task characteristics
l Connecting relation between
assembly processes
Automatic
assembly
Manual
assembly
BK21LogisticsTeam, July2000 9
Table 2. Automation possibility of grease application
T4(Available workpiece carrier). Arrangement area is divided A1(Possible continuous
arrangement), A2(Possible arrangement minimal controlling), A3(Available arrangement
device) and A4(No tangling in arrangement). Feeding area is divided F1(Possible continuous
feeding), F2(laying stability after feeding), F3(Available feeding device) and F4(Possible grasp
in feeding). Joining area is divided J1(Possible simple assembly method), J2(Easy grasp),
J3(Possible automation assembly) and J4(No additional adjustment or easy additional
adjustment after joining). For example, the score of 1 of T1 that is one of standards for
transporting in transporting area means that we can get information for automation possibility of
grease application harder.


















Table 2 shows a calculation method and result of grease application process. The evaluation
criteria of each area are extracted to calculate a point of automation possibility, and degree of
possibility can be obtained. For instance, in this process, automatic transporting of parts is most
difficult compared with other area, and the total point of automation possibility is -12 . Using
this method the automation possibility of all process is determined, and they are compared to
decide an automation priority.
3.2 Determination of assembly equipment of assembly process
After determination of automation possibility of each assembly process, we determine the
method and machine of transporting, arrangement, feeding. Assembly machines and equipments
are determined on only process that is performed by automation assembly. Assembly machine
equipment is determined by characteristics of process.
Therefore, this research is consisted of three numbers of for ABS motor assembly; armature
bearing placing m/c, holder yoke placing m/c, motor tester m/c. Armature bearing placing m/c is
performed assembly of yoke subassembly, brush and check of bolt height and assembly of
armature and bearing insertion. Hold yoke placing m/c is performed insertion of yoke and
magnet hold subassembly. Meter Tester m/c is performed aging, S/F check, check of shaft
Determination of automation possibility of
each area functional factor
Criteria Degree Criteria Degree
T1 -1 A1 -1
T2 -1 A2 +1
T3 -2 A3 -1
T4 -1 A4 -2
T
r
a
n
s
p
o
r
t
i
n
g

Sum -5
A
r
r
a
n
g
e
m
e
n
t

Sum -3
F1 0 J1 +1
F2 +1 J2 -1
F3 -1 J3 0
F4 -2 J4 -1
F
e
e
d
i
n
g

Sum -2
J
o
i
n
i
n
g

Sum -1
-2: very difficult
-1: difficult
0:same +1:easy
+2:very easy
Total
point
-12

10 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
length, bolt, voltage, turning direction check, load check, etc. Fig.4 shows the assembly process
that is accomplished by the placing M/C of armature bearing and motor tester M/C. For instance,
the assembly process joining of bearing and yoke, check of bolt height and brush, fixing of
brush and joining of armature and bearing are performed by placing M/C of armature and
bearing.











Fig. 5 Working position of placing M/C
Fig. 5 shows the all assembly position of assembly of assembly work in placing m/c of
Armature bearing. It carries out this assembly on revolving 4 indexing table. That is, Position 1
is the place of joining of bearing and yoke subassembly, it is checked of the bolt height and
brush at position 2, position 3 is fixing of brush and position 4 is joining of armature and

Jig Bearing
Housing Ass y
Armature
Joining of bearing
and yoke
Check of bolt
height and brush
Cheker
of bolt
Jig
Brush
checker
Fixing of brush
Brush
contact jig Clamp
Joining of armature
and bearing
Placing M/C of
armature, bearing
Motor
Load
checker
Aging
Check of shaft
length, bolt
Voltage, turning
direction check
Turning
direction:CW
Motor
Load check
Checker
of bolt
height
Eccentricity checker
Motor tester M/C
Fig. 4 Assembly processes by placing M/C and tester M/C
Position 2
1000mm
450 550
5
5
0
1
2
0
0
P
o
s
i
t
i
o
n

1
L
o
a
d
/
u
n
l
o
a
d
Position 3
Position 4
Checker
BK21LogisticsTeam, July2000 11
bearing place. Fig. 6 shows assembly work in holder yoke placing m/c. That is, it shows sketch
and work position of magnet and holder subassembly and yoke insertion. After insertion of
magnet holder subassembly or bearing into jig of placing m/c, it puts yoke at proper position,
operate device insertion and finish insertion.










Fig. 6 Assembly processes of holder yoke placing M/C

3.3 Layout of assembly machinery equipment
The basic objective of machinery equipment and facility layout in assembly system is to
improve a assembly productivity and the detail objectives are a to be the smooth inner
transporting, efficient place utilization, consideration of safe of machinery and equipment, and
creation of safe and comfortable inner circumstance for worker, etc.
The necessary of information and data that are needed to plan and determine of equipment
placement are production capacity, form of production and process, machinery equipment and
plants, inner system and amount of transporting, amount of work of each position and form and
size of plants. There are several equipment layouts; product layout(line layout), process layout,
fixed position layout.
In this research, we use two layouts; first, we used efficient and prompt product layout
because we product one special item of ABS motor. Second, we used mixed layout that also
used process layout , which has test equipments in one place because most of test processes
need when a product is finished. Actually, there are coexistence forms of different layout,
though we distinguished these three layout forms strictly in the above. The required space to
assembly lines of ABS motor is 3920mm, 57300mm. In this space, it is impossible and
inefficient that equipments like a straight line is determined.
So, we choose U-line like Fig. 7 in order to efficient rationing and flexible production. The
advantages of U-line improve line balancing and work efficiency with minimizing of the size of
Joining of magnet
holder and yoke
Joining of yoke and
bearing
Holder Yoke
Placing M/C
Yoke
Magnet
Holder
Ass y
Yoke
Bearing
Position 1
Position 2
12 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
space used and movement distance of worker in a coexistence of manual and automation line.
See the Fig.7 below, the network that is left side figure shows related and adjoined forms
simultaneously considering between machinery equipments and assembly sequence. And then,
we determined U-line like right side of this figure with modification of this network. A solid
line indicates that it can reduce transporting distance and cost when it adjoins each other. A
point solid line indicates a little relation when we consider layout or layout modification.











Fig. 7 Activity relation graph and line type of motor three layout forms strictly.

3.4 Work assignment and line balancing
In assembly line balancing, we have to adjust the required work time of each work place to
assembly and manufacturing work with making almost same extent of production period. This
line balancing has been studied as Heuristic approach though it has been studied mathematical
proofs. That is, it is a kind of technique that we expect good plan, we can t assure that it is the
best thought. Some techniques well known of heuristic approach are Kilbridge-wester, ranked
positional weight heuristic, etc.
In this research, we apply three types assembly line balancing. There are Kilbridge-wester
method, standard work assignment method and improved heuristic method. Improved heuristic
method allocates their work shares through 7 levels below.
Level 1 Grasp the target value of cycle time and limitation of priority constraints.
Level 2 Determine positional weight of each work
Level 3 Put a ranking in order of high PW of each work
Level 4 Put a ranking in priority succession process order of each work (If there are same rates,
9
2
3
4
10
12
13
14
15
1
5
8
11
6
7
4 3 2
6
7
10
12
14
13
15
1
5
9
8
11
BK21LogisticsTeam, July2000 13
choose a work which has big Task time)
Level 5 Combine level 3 and 4. And output total rank about each work
Level 6 Allocate each work to work place in posteriority TR order.
Level 7 Select a method that can minimize slack time in each work place.
Fig.6 shows the result of assembly line allocation of each work through assembly line balancing
of ABS motor with three methods above. Cycle time is division assembly time by assembly
yield and the assembly time per a unit.
For example, using a standard work task table, if we intend to produce 15,000 outputs per a
month, which has 22days, the output will be 682, and a standard for working hours is 10 hours
25 min, that is 36099 sec, so the cycle time which is divided work time by work output is 54sec.
Therefore, if we want to 682 outputs, we should produce one motor per 54sec. And next, we
determined the number of workers by considering of net assembly time of machine and
handling time of worker. Generally, working time is handling time itself. But, this assembly line
contains assembly time of machinery as well as handling time of subassembly. `

The line efficiency of equation (3.2) and smoothness Index of equation (3.3) are used to indicate
efficiency of assembly line balancing
In these formulas, K means the number of workers, CT is a cycle time, N is assembly
process, T
i
is a working hours of each worker, and T
max
is the maximum working hours of
each worker




Production
volume
5000 units/month 10000 units/month 15000 units/month
Heuristic Worker Assigned process Sec Worker Assigned process Sec Worker Assigned process Sec
1 9,8,11,13,14,15 119 1 11,13,14,15 81 1 11,12 49
2 8,9,7,10,12 77 2 8,9,10 48
2
5,1,2,3,4,6,7,
10,12
107
3 1,5,2,3,4,6 68 3 13,14,15 47
4 5,6,7 39
5 1,2,3,4 43
Standard
work
assignment
method CT=162sec, LE=93.3%, SI=12 CT=81sec, LE=91.4%, SI=13.6
CT=54sec, LE=90.6%, SI=11.5*
1 11,8,2 74 1 11,1 49
1
11,8,2,1,3,9,4,
7,6
154
2 1,3,9,5,4,7,6 80 2 8,2,3 48
2 10,12,13,14,15 72 3 10,12,13,14,15 72 3 9,5,4,7 47
4 10,12,13 41
5 6,14,15 41
Improved
heuristic
method
CT=162sec, LE=72.1%, SI=82 CT=81sec, LE=92.5%*, SI=10*
CT=54sec, LE=90.6%, SI=11.5*
1 11,8,2 74 1 11,1 49
1
11,8,2,1,3,9,4,
7,6
154
2 1,3,9,5,4,7,6 80 2 8,9,5 53
2 10,12,13,14,15 72 3 10,12,13,14,15 72 3 2,3,4,7,6 52
4 10,12,13 41
5 14,15 31
Kilbridge-
wester
method
CT=162sec, LE=72.1%, SI=82 CT=81sec, LE=92.5%*, SI=10*
CT=54sec, LE=83.4%, SI=25.4
1
5 54 222
1

1
1
1
1

CT T K
N
i
i
(3.1)
Table 3. Assembly processes by placing M/C and tester
14 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
% 6 . 90 % 100 ) )( (
1

'

CT K T LE
N
i
i
(3.2)
Fig. 8 Alternative of assembly line by line balancing





The indices are used when it is compared that assembly line balancing and work allocation of
more than one. Line efficiency is good value if its value is high, and bad value if its value is low.
If value of smoothness index is low, line balancing improves than value of smoothness index is
high.
In Table 3, line efficiency and smoothness index, which are calculated by standard work
assignment method, are resulted as good value when it produce 5000 motors per month. But
relatively, improved heuristic method is given as bad value because this value is only dependent
on cycle time. Therefore, when motor is produced number of 5000, it is best way to allocate by
using the table of standard work assignment, and then experientially repeating trade-off, that is,
assignment value of workstation in this table. Both of improved heuristic method and Kilbriede-
wester method can be proposed as appropriate heuristic method in case of number of 10,000.
And standard work assignment method and improved heuristic method can be proposed as
appropriate heuristic method in case of number of 15,000, both heuristic methods are show in as
the same results, 90.6% of line efficiency and 11.5% of smoothness index. Though two heuristic
methods have a same value of LE and SI as shown in Table. 3, they have a little difference of
types and number of assembly task that are allocated to the worker.


As shown in Fig. 8, in case of number of 10,000 per month, U-line can be considered as
improved heuristic method and Kilbriede-wester method considering optimal work allocation,
transporting pass of work, type of work and work sequence. As shown in Fig. 8, in case of
15,000 per month, U-line cab be considered as standard work allocation method, optimal work
allocation, transporting pass of work, type of work and work sequence.
5 . 11 ) (
1
max

N
i
i
T T SI (3.3)
Production vol. 15000 /month
CT 54 sec No. of worker 5 CT 81 sec No. of worker 3
Production vol. 10000 /month
Sticker,
packing
Airtight
test
Aging
Load
checker
Magnet
ization
of
magnet
Bolting
Silicone
application,
yoke
insertion
Pig tail
control,
air supply
Bearing
and yoke
assembler
Holder
and yoke
assembler
Magnet
and holder
assembler
Spring
insertion to
brush holder
Grommet
insertion
H
bolting
Rotor
And
bearing
assembler
Air supply,
O- ring
insertion,
grease
1
2
3
Sticker,
packing
Airtight
test
Aging
Load
checker
Magnet
ization
of
magnet
Bolting
Silicone
application,
yoke
Pig tail
control,
air supply
Bearing
and yoke
assembler
Holder
and yoke
assembler
Magnet
and holder
assembler
Spring
insertion to
brush holder
Grommet
insertion
H
bolting
Rotor
And
bearing
assembler
Air supply,
O-ring
insertion,
grease
5
4
2
1
3
Production vol. 15000 /month
CT 54 sec No. of worker 5 CT 81 sec No. of worker 3
Production vol. 10000 /month
Sticker,
packing
Airtight
test
Aging
Load
checker
Magnet
ization
of
magnet
Bolting
Silicone
application,
yoke
insertion
Pig tail
control,
air supply
Bearing
and yoke
assembler
Holder
and yoke
assembler
Magnet
and holder
assembler
Spring
insertion to
brush holder
Grommet
insertion
H
bolting
Rotor
And
bearing
assembler
Air supply,
O- ring
insertion,
grease
1
2
3
Sticker,
packing
Airtight
test
Aging
Load
checker
Magnet
ization
of
magnet
Bolting
Silicone
application,
yoke
Pig tail
control,
air supply
Bearing
and yoke
assembler
Holder
and yoke
assembler
Magnet
and holder
assembler
Spring
insertion to
brush holder
Grommet
insertion
H
bolting
Rotor
And
bearing
assembler
Air supply,
O-ring
insertion,
grease
5
4
2
1
3
BK21LogisticsTeam, July2000 15
Table 4. Work allocation of each worker
If the target product volume is number of 10,000, the cycle time is 81second. And in this time, 3
workers are needed for one motor production. If the target product volume is number of 15,000,
cycle time is 54second. And in this time, 5 workers are needed for one motor production.















Table 4 shows an allocating process of worker, work time and movement distance. W is worker,
S is work sequence, P is allocated process and D is movement distance. The number of
allocated process, assembly time and movement distance of each work is different. But total
assembly time and movement distance can be adjusted uniformly by line balancing. Like
automation assembly, in case of automatic assembly and manual assembly is mixed, its total
work time of each work has to similar through line balancing. Specially, movement distance has
to be considered. Because movement distance of figure shows the case of when one motor is
produced. If the number of motor is many, movement distance can be different.
Therefore, it has to accomplish work exchange per time and work reallocation through
determination of movement distance of each work and degree of work fatigue, etc.




Production volume: 10,000units/month
W S P T D W S P T D
1 11 34 2.3 6 7 14 0.7
2 8 28 0.8 7 6 10 0.8
3 2 12 0.7
2
Sum 80 5.3
1
Sum 74 3.8 1 10 10 3.7
1 1 15 1.0 2 12 15 0.7
2 3 8 0.7 3 13 16 0.6
3 9 10 0.7 4 14 15 1.2
4 5 15 0.8 5 15 16 0.5
2
5 4 8 0.6
3
Sum 72 6.7
Production volume: 15,000units/month
W S P T D W S P T D
1 1 15 1.3 1 8 28 0.8
2 2 12 0.6 2 9 10 1.0
3 3 8 0.4 3 10 10 1.0
4 4 8 1.2
3
Sum 48 3.8
1
Sum 43 3.5 1 11 34 1.2
1 5 15 1.2 2 12 15 1.2
2 6 10 0.8
4
Sum 49 2.4
3 7 14 1.0 1 13 16 2.0
2
Sum 39 3.0 2 14 15 0.7
3 15 16 0.8
Unit: time-sec., distance-m
5
Sum 47 3.5
16 Implementation and Line Balancing of Assembly Line of ABS Motor
for Improvement of Assembly Productivity
4 Conclusion
In this research, we implemented a assembly system of final assembly process of automobile
ABS motor. There are 4 subassemblies of ABS motor; yoke, housing, grommet, and armature.
But we can't automate these completely because of their geometric and assembly process
characteristics and some considerations of assembly cost, required place, etc.
So, we constructed mixing form of automation assembly and manual assembly. First, we
established assembly order with grasp of assembly process. Second, we classified the whole
assembly process into each unit and decided the automation possibility of each process. In
manual assembly, we decided methods of transporting, arrangement, feeding and joining, and in
automation assembly, we determined machinery equipment according to assembly mechanism.
And we also make U-line layout for efficient arrangement of assembly equipment that is
decided by unit process.
It helps to minimize time of worker's movement and assembly. Finally, we allocated assembly
work of each worker by realizing assembly line balancing after deciding the number of workers
who can produce the target yield. And we estimated the efficiency of constructed assembly line
with the index of line estimation like as line efficiency and leveling index.

















BK21LogisticsTeam, July2000 17
5 Reference

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pp.181-208.
Elsayed A., Thomas O., 1994, Analysis and Control of Production System, Prentice Hall, pp.
344-402.
Francis, R. L., McGinnis, L. F. and White, J. A., 1992, Facility Layout and Location: An
Analytical Approach, Prentice Hall, pp.27-184.
Frank J., 1996, Assembly Automation, Industrial Press Inc., pp. 47-77.
Lotter, B., 1989, Manufacturing Assembly Handbook, Butterworths, pp.303-383.
Redford, A. and Chal, J., 1994, Design for Assembly, McGraw-Hill, Inc., pp. 75-134.
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