A NEW MODEL PROPOSAL FOR ERGONOMIC ASSEMBLY LINE BALANCING

Year 2019, Volume: 7 Issue: 4, 767 - 778, 19.12.2019

Emin Kahya , Büşra Nur Şahin

https://doi.org/10.21923/jesd.468028

Cited By: 3

Abstract

Assembly line balancing is a problem where tasks assign to stations in
compliance with precedence constraints and as far as possible to balance
delays. Assembly lines which is not designed properly in an ergonomic way cause
not only productivity loss but also work-related muscoloskeletal disorders on
workers. To prevent such problems, it should be aimed to catch acceptable level
for each workstation’s risk score and assign ergonomic risks equivalently among
workers. In this study, for assembly line balancing problem, a new model
approach is tackled, which constitute stations by consider ergonomic risk
scores in addition to cycle time and precedence constraints. In order to
compare proposed model with a classical assembly line balancing technique, a
performance criterion which is combination of cycle time and ergonomic risk
score were defined. The developed model was applied in a factory’s oven
assembly line. In the assembly line, task times were measured, precedence
diagram was constructed and ergonomic risk levels were evaulated by using REBA
method. When balancing lines with using Longest Operation Times technique,
performance score was %25.61 but when it comes to balance with developed model
performance score was obtained %18.25. It has been detected that developed
model provides 7.41% improvement in line’s total performance.

Keywords

Assembly Line Balancing, Ergonomic Risk Evaulation, REBA

ERGONOMİK MONTAJ HATTI DENGELEME İÇİN YENİ BİR MODEL ÖNERİSİ

Abstract

Montaj hattı dengeleme probleminde
yapılacak işlemler, hattın belirlenen hızda devam etmesi amacıyla ve öncelik
ilişkilerini dikkate alarak dengeli bir şekilde istasyonlara atanır. Montaj
hattı ve istasyonların tasarımında ergonomik düzenlemeler göz ardı edildiğinde,
çalışanlarda kas iskelet sistemi hastalıklarına ve devamında verimlilik
kayıplarına da yol açabilir. Çalışan sağlığını ve üretimin verimliliğini
korumak için montaj hattı dengelemede her bir istasyonun ergonomik risk
düzeyinin kabul edilebilir seviyeye çekilmesi ve zorlanma düzeyinin işçiler
arasında dengeli dağıtılması da amaçlanmalıdır. Bu çalışmada, montaj hattı
dengelemede, öncelik ilişkileri ile çevrim süresi kısıtına ilaveten, ergonomik
risk düzeyini de dikkate alan yeni bir model geliştirilmesi amaçlanmıştır. Ayrıca,
önerilen modelin klasik montaj hattı dengeleme modeli ile karşılaştırılması
amacıyla, süre ve ergonomik risk düzeyinin bileşkesinden oluşan performans
ölçütü tanımlanmıştır. Geliştirilen model, bir işletmenin fırın montaj hattı
için uygulanmıştır. Her iki montaj hattında işlem süreleri ölçülmüş, öncelik
ilişkileri çıkarılmış ve REBA yöntemi ile ergonomik risk düzeyleri
hesaplanmıştır. En Büyük Aday yöntemi kullanılarak yapılan klasik montaj
dengelemede, performans skoru %25.61 olurken, geliştirilen model için %18.25
elde edilmiştir. Geliştirilen modelin, toplam performansda %7.41 iyileştirme
sağladığı tespit edilmiştir.

Keywords

Montaj Hattı Dengeleme, Ergonomik Risk Değerlendirme, REBA

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