Line Balancing Study Using Value Stream Mapping Tool on Lean Manufacturing: A Case Study in an Electronic Industry

Abstract

 XY Electronics, a leading international company in electronic components manufacturing, is confronting significant production constraints that adversely affect output, lead times, and operational expenses. This study examines the manufacturing line for product A using Value Stream Mapping to analyze process times and identify bottlenecks where takt times are exceeded. It focuses on areas surpassing production cycle times and aims to enhance line utilization through better line balancing and waste reduction. The results reveal that the header assembly, along with coplanarity and pre-testing 3, are major bottlenecks, which significantly impact productivity. By optimizing task allocation, refining workforce distribution, and employing cross-training, the production line efficiency improved significantly. In addition, strategic workforce reallocation and station optimization were crucial in addressing resource underutilization and enhancing overall operational efficiency