LINE BALANCE DEVELOPMENT & IMPLEMENTATION

operator balancing

SERVICE AREA:

IMEG was contracted by a startup Electric Commercial Truck manufacturer to improve throughput through effective line balancing. The facility featured a 15-station assembly line in a 200,000 sq. ft. space, with no budget allocated for physical layout changes.

THE PROBLEM

Stations had an uneven distribution of process time across assembly stations, hindering production efficiency
Physical layout constraints from fixed equipment and limited space
Zero budget available for layout modifications
A tight timeline for implementing necessary improvements

THE PLAN

IMEG implemented a strategic line balance development plan that accounted for production, layout, and labor limitations:

Observed and analyzed the existing assembly line processes
Collected and validated time study data to model the optimal balance
Calculated takt time aligned with customer delivery goals
Designed a manning strategy to optimize labor usage without additional headcount
Introduced supplemental process improvements to reduce overall cycle time

assembly line optimization

THE RESULTS

Our line-balancing project delivered immediate performance gains and long-term process improvements:

Developed a comprehensive line balance strategy targeting a 20% efficiency increase
Achieved a 35% increase in throughput by implementing the plan ahead of schedule
Balanced processes across 15 assembly stations, streamlining workflow
Implemented flexible manning strategies to meet demand without increasing labor
Reduced total cycle time through targeted process enhancements
Positioned the manufacturer for scalable growth and future optimization