ERGONOMİK MONTAJ HATTI DENGELEME PROBLEMİNİN FARKLI RİSK FAKTÖRLERİ İÇİN MODELLENMESİ VE ÇÖZÜMÜ

Yıl 2023, Cilt: 34 Sayı: 3, 433 - 457, 31.12.2023

Sena Gülbandılar Canbazoğlu Emin Kahya

https://doi.org/10.46465/endustrimuhendisligi.1329111

Öz

Montaj hattı dengeleme problemleri, akış odaklı bir üretim sisteminde gerekli tüm görevlerin iş istasyonlarına verimli ve etkili bir şekilde atanmasını amaçlar. Fakat montaj hatlarında meydana gelen tekrarlı işler ve statik duruşlar sebebi ile çalışanlarda Kas-İskelet Sistemi Rahatsızlıklarına sebep olmaktadır. Bu çalışmada, sadece istasyon sayısını azaltmayı hedefleyen değil aynı zamanda ergonomik zorlanmayı da dengeleyen bir montaj hattı probleminin ele alınması amaçlanmıştır. İstasyonlarda yer alan iş elemanları için zaman etüdü ile işlem süreleri ve istasyon başına düşen ergonomik risk değerleri REBA yöntemi ile belirlenmiştir. Bir ağır ticari araç işletmesinin motor montaj hattında 24 istasyonda 198 iş elemanı için çevrim süresi 14,31 dakika, toplam dengeleme gecikmesi 42,64 dakikadır. Bu hatta REBA skorları 6 ile 55 arasında değişmektedir. GAMS paket programı ile montaj hattı dengeleme probleminin optimum çözümü ile atamalar yapılmış, yapılan çözümlemelerde istasyon sayısı 23 ve toplam dengeleme gecikmesi 28,33 dakika elde edilmiştir. Ergonomik risk kısıtı içeren çözümde ise istasyon sayısı 29’a yükselirken toplam dengeleme gecikmesi 114,39 dakika hesaplanmıştır. Ancak istasyon başına düşen REBA skorlarının dağılımı 6 ile 30 arasında değişkenlik göstermiştir. Modelde; mevcut ortalama ergonomik risk kısıtı için farklı tolerans payları ile, ağırlıklı ergonomik risk kısıtı içeren model ve değişken üretim talebi doğrultusunda oluşturulan yeni hedefler ile çözdürülerek duyarlılık analizi yapılmıştır.

Anahtar Kelimeler

Montaj Hattı Dengeleme, Ergonomik Risk Değerlendirmesi, REBA

MODELING AND SOLUTION OF THE ERGONOMIC ASSEMBLY LINE BALANCING PROBLEM FOR DIFFERENT ERGONOMIC RISK RESTRICTIONS

Öz

Assembly line balancing problems aim to assign all required tasks efficiently and effectively to workstations in a flow-oriented production system. However, due to repetitive work and static postures on assembly lines, it causes Musculoskeletal Disorders in employees. In this study, it is aimed to address an assembly line problem that not only aims to reduce the number of stations but also balances the ergonomic strain. Time study and operation times and ergonomic risk values per station were determined by the REBA method for the workers in the stations. In the engine assembly line of a heavy commercial vehicle enterprise, the cycle time is 14.31 minutes and the total balancing delay is 42.64 minutes for 198 workers at 24 stations. In this line, REBA scores range from 6 to 55. With the GAMS package program, the assignments were made with the optimum solution of the assembly line balancing problem, the number of stations was 23 and the total balancing delay was 28.33 minutes in the analysis. In the solution containing ergonomic risk constraint, the number of stations increased to 29, while the total balancing delay was calculated as 114.39 minutes. However, the distribution of REBA scores per station varied between 6 and 30. In the model; Sensitivity analysis was carried out by solving it with different tolerance margins for the current average ergonomic risk constraint, with the model containing the weighted ergonomic risk constraint, and with new targets created in line with the variable production demand.

Anahtar Kelimeler

Assembly Line Balancing, Ergonomic Risk Assessment, REBA

Kaynakça

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