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CANDRA, SEVENPRI

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Ford Lumban Gaol, S.Si, M.Kom., Dr.

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Johan J.C. Tambotoh, Sani M. Isa, Ford
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Hendric Spits Warnars. "Software quality model
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Witold Suryn. "The applicability analysis of
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Similarity "Software quality model for Internet of Things governance"

Soewito, M.Sc., Ph.D, Benfano

Digital Technology: The Effect of Connected World to Computer Ethic and Family

Reviewer Form An automatic text summarization using text features and singular value decomposition for popular articles in Indonesia language

Fergyanto E. Gunawan, S.T., M.T., Eng., Dr.

Design and Implementation of Discrete-event Simulation Framework for Modeling Bus Rapid Transit System

Oktavia, Tanty

Peer Review "The General Components of e-Learning Framework for Higher Institution: A Systematic Literature Review"

Suharjito, Suharjito

Modeling Software Effort Estimation Using Hybrid PSO-ANFIS

2016 International Conference on Information Technology Systems and Innovation (ICITSI) 
Bandung – Bali, October 24 – 27, 2016 
ISBN: 978-1-5090-2449-0 
 
Improvement Of Production System Efficiency and 
Production Capacity Using Line Balancing Method 
aSyerly Setiana, bSevenpri Candra, aAditya Andika 
aDepartment of Industrial Engineering 
bDepartment of Management 
Bina Nusantara University 
Jakarta, Indonesia 
aditya.a@binus.ac.id  
 
 
Abstract— This study discusses the research results 
conducted on an Indonesian plastic manufacturing company. The 
distribution of the workload in a production process needs to be 
calculated so that the company is able to achieve the target of 
production. This research was conducted to improve the 
efficiency of production systems and the production capacity of 
the company so that the company is able to meet production 
targets. The method used in this study is line balancing. Time 
study method is conducted to calculate cycle time and then 
forecasting method is utilized to determine production target and 
required cycle time. After that, 3 methods of line balancing: 
ranked positional weights, Moodie Young and new bidirectional 
is used. The result of the line balancing method shows that the 
best methods are Moodie Young and new bidirectional with the 
efficiency of 82.97%, much higher from the current state, which 
is only 48.89%. The number of workstation is also decreased 
from 9 to 7. The production also increased from 780.41 pieces per 
day to 1,030.07 pieces per day.  
Keywords— line balancing; ranked positional weight, Moodie 
& Young; New Bidirectional method; plastic manufacturing 
I. INTRODUCTION 
In this globalization era, many changes and developments 
that occurred changed the mindset and forcing companies to 
be more advanced. Therefore it is important for the company 
to provide the best product or service to the consumer so that 
the company can compete in the market.  
Operations management is a set of activities that produce 
value in the form of goods or services by transforming inputs 
into outputs [1]. If the division of the workload of each work 
station is different, so the production process can be 
interrupted.  
Method that can be used to balance the production line is 
the line balancing. Line balancing is a technique to spread the 
load of work in all processes in the cell or value stream to 
remove bottlenecks [2]. An Indonesian plastic manufacturing 
company is facing problems in its plastic bag production line. 
Fig. 1. shows that the company still difficult to meet 
production targets, where the amount of production per month 
is always lower than the production target should be. Non-
fulfillment of production targets is because there is a division 
of the workload that is not balanced in each work station. 
 
 
Fig. 1. Comparison of Actual Production and Production Target 
 
 The condition forces the company to add overtime to meet 
production targets. This ultimately makes the company 
overtime hours increased and exceeded the company's policy 
that only allows a maximum of 2 hours. 
 The company needs to balance the line to make its line 
more efficient. 
II. LITERATURE STUDY 
A. Time Study 
 
The cycle time (cycle time) is the period of time required 
to complete an operation. Calculation of the cycle time can use 
the following formula [3]: 
 
C = TN 
 (1) 
Where: 
C = Cycle Time; T = Production time per day; N = Total 
Production per day 
 
Normal time can be calculated using this formula [4]: 
 
Normal Time = Cycle Time x  % Performance100%  
 (2) 
978-1-5090-2449-0/16/$31.00 ©2016 IEEE
The standard time is the overall time required by a worker 
or operator who has average ability to complete a job. 
Standard time can be calculated using this formula [4]: 
 
Standard Time = normal time x 100%100%-% allowance 
 (3) 
 
To determine the normal distribution of data, Kolmogorov-
Smirnov test was used. If the value of the data significance is 
greater than the error level, which usually is 5% then the data 
is normal [5]. 
 
To conduct uniformity test, Upper control limit (UCL) and 
lower control limit (LCL) is calculated by using the following 
formula [4]: 
 
UCL = Mean + 3 Standard Deviation (4) 
LCL = Mean - 3 Standard Deviation (5) 
 
 Test adequacy observation data needs to be done in order 
to know whether the data that have been taken have been 
sufficient. The formula for calculating the data adequacy test 
are as follows [4]: 
 
 









−
=
)X(
)X(XN
s
k
 N'
i
2
i
2
i
 (6) 
 
Where:  
N’= Number of observations / observations should be made 
N= number of observations that have been made 
Xi= Data element i 
K = Confidence level = 95%, k = 2 
S = Level of accuracy= 5% = 0.05 
If N’<N then data are adequate. 
 
B. Line Balancing 
The efficiency of the line is the calculation of the 
efficiency of the existing work time as a result of the line 
balancing. Can be calculated using the formula [3]: 
 
HE = TN.C  x 100% 
 (7) 
Where: 
HE = Line Efficiency; N = Total work station; C = cycle time; 
T = Work time per day 
Smoothing index is an index that describes the smoothness of 
line balancing. The minimum value is 0. The following 
formula is used [6]: 
SI=ඩ෍ (STmax-STi)2
N
i=1
 
 (8) 
Where: 
STmax= Maximum time of work stations  
STi= Minimum time of work station 
Balance delay is the calculation of inefficiencies caused by the 
imperfection of work allocation between work stations [7]: 
 
BD =  
N.Tc - ∑ Tei
N.Tc
 x 100% 
 (9) 
Where: 
BD = Balance delay; Tei = Total time in production line; N = 
Total work station; Tc = Maximum Cycle Time 
 
Line balancing methods: 
1. Rangked Positional Weights (RPW) 
 RPW method can be explained as follows [8]: 
1. Calculate the desired speed. 
2. Create a preliminary matrix  based on network assembly 
work 
3. Calculate the weight of each operation based on the 
amount of time the operation and the operations that 
followed. 
4. Sort operations ranging from the position of greatest 
weight to the weight of the smallest position. 
5. Place operations at the work station with weights ranging 
from the largest position until the weight of the smallest 
position with the criteria that total operating time is smaller 
than the given track speed. 
6. Calculate the average efficiency of the work stations are 
formed 
7. Use trial and error procedure to seek the imposition of 
which would produce an average efficiency greater than 
average efficiency at the point 6 above. 
8. Repeat step 6 and 7 
 
2. Moodie Young 
Moodie Young method has two phases [9]: 
The first phase: 
Make grouping work stations. Working elements 
placed at the work station with the rules, if there are two 
elements of work that could have the elements of work that 
has a larger time placed first. In this phase also, from the 
precedence diagram created matrix P and F, which describes 
the work element precursor (P) and the elements of work that 
follow (F) for all elements of the existing work. 
 
 
The second phase: 
1. The identification of a work station and a work station the 
smallest. 
2. Calculate GOAL = (Max Cycle Time – Min Cycle Time)/2 
3. Identification of a working element contained in the work 
station with the maximum time, which has a smaller time 
than GOAL, move that element if when it was moved to 
the work station, it does not violate the precedence 
diagram. 
4. Move the working elements. 
5. Repeat until no more evaluation elements of work that can 
be moved 
 
3. New Bidirectional 
New Bidirectional method consists of four steps [10]: 
1. Determining the critical path, then separate the elements of 
work that is in the critical path (Scp) and which are not 
(S’cp) 
2. Creating a temporary work station (FS and BS) 
3. Allocate element of the critical path that has no 
predecessor to the FS and which does not have followers to 
BS, allocate elements not to exceed the cycle time. 
4. Calculate the value Wf and Wb to determine the 
permanent work stations. If Wf ≤ Wb then make 
permanent FS station and vice versa. Complete this step is 
repeated until all the elements are allocated. Stop until FS 
= BS. 
 
III. RESEARCH METHOD 
The study began by literature study, accompanied by 
preliminary observations. Data were collected by interview, 
observation and literature study. The analysis method used is 
by using time study, forecasting, and line balancing are 
integrated with each other. Time data of each work element is 
found, then do the normality test, uniformity test and test the 
adequacy of using time study, then the data cycle time 
obtained is used to calculate the efficiency of production 
systems now with the method of line balancing, after it to 
make the proposal takes a new cycle in which this time can 
meet the demand, so do forecasting demand in advance using 
the methods of forecasting and can then be calculated the 
cycle time required. After the cycle time required is obtained 
then calculate the proposed system with line balancing method 
that consists of 3 methods: RPW, Moodie Young, and New 
Bidirectional. Afterwards, the best method is selected based 
on the results. 
 
IV. RESULT AND DISCUSSION 
A. Data Of Work Element Time 
Preliminary data needed to perform the calculation of 
line balancing is to collect the data elements of the work and 
time of each element work. After observation there are 27 
elements of work with 9 work stations for plastic bag 
production process. Data elements of work can be seen in 
TABLE I. 
TABLE I. WORK STATION AND WORK ELEMENT 
 
Work Stations No Work Element 
A 
(Cord) 
1 Fetch cord 
2 Measuring the length of the cord 
3 Cutting the cord 
4 Merger cord 
5 Combustion end of the cord 
6 Put the cord to a container 
B 
(Cutting) 
7 Put plastic roll to cutting manual 
8 Plastic Length Measurement 
9 The process of cutting manual plastic roll 
10 Put the plastic to container  
C 
(Pressing) 
11 Setting press machine 
12 Pressing the plastic 
13 Put the result of pressing into the container 
D 
(Perforations) 14 Perforations plastic 
E 
(Sewing) 
15 Installation of the needle into the cord 
16 Sewing 
17 Put the sewing results to container 
F 
(Installation of 
Cover Cord) 
18 Fetch the ends of the rope 
19 Installation of the cover to the end of the cord 
20 Put the plastic into container 
G 
(Folding) 
21 Checking product  
22 Plastic folding  
23 Put the results folds into a container 
H 
(Packaging) 
24 Fetch packaging 
25 Insert plastic to the packaging 
I 
(Sealing) 
26 Setting heat sealer machine 
27 The process of sealing the packaging 
 
B. Normality Test, Uniformity and Sampling Adequacy Test  
Below are the results of the sampling adequacy test, 
normality test, and uniformity test of the data. 
 
  
 Fig. 2. Sampling Adequacy Test 
In Fig. 2, data are adequate because N’<N. 
  
Fig. 3. Normality Test  
 
In Fig. 3, sig > α then the data is a normal data. 
 
 
Fig. 4. Uniformity Test 
 
In Fig. 4, UCL> Mean > LCL, then the data is uniform. 
 
C. The Calculation of Standard Time  
For the calculation of line balancing required standard 
time of each work elements. To calculate the standard time it 
takes the average cycle time, performance rating, the normal 
time and work allowance. Calculation of normal time using a 
performance rating of 8% and the computation time using the 
standard allowance of 14%. The results can be seen in the 
standard time column of TABLE II, TABLE III, and TABLE 
IV. 
 
D. The  Efficiency of Current Production System 
Then, the cycle time calculation system is now 
calculated using total production of one year of data generated 
by the company which is 232.563 pieces, then divided by the 
number of days in the year (298 days) to obtain estimates of 
units produced per day. So total unit produced per day is 
232,563/298 = 780.41 pcs plastic bag/ day.  
 Calculation of the present production system cycle 
times are as follows: 
Cycle time= 73.81 Second. 
 
E. Forecasting Calculation 
Forecasting calculation is needed to calculate the cycle 
time that needed. Trend analysis forecasting is used. From the 
forecasting result, production rate per day is 307,993/299 = 
1030.07 pcs. Then, we can calculate the cycle time that 
needed: C = T/N =  57,600/1,030.07 = 55.92 second. 
F. Line Balancing RPW Result 
Here in Table 2, is the result of weighting by using the 
method of RPW. 
 
TABLE II. RPW RESULTS 
 
Station Element Weight Standard Time 
Total Time  
( Second) 
A 
7 258.78 10.12 
46.29 
8 258.78 9.85 
9 248.93 13.23 
10 235.70 2.74 
1 233.59 3.00 
11 232.96 7.35 
B 
2 230.59 12.09 
40.02 12 225.61 21.46 
3 218.50 6.48 
C 
4 212.02 19.21 
45.63 13 204.15 3.11 
14 201.04 23.31 
D 
5 192.82 12.30 
22.96 6 180.52 2.79 
15 177.73 7.87 
E 
16 169.85 50.43 
54.47 17 119.43 2.54 
18 116.88 1.49 
F 
19 115.39 20.88 
36.55 20 94.51 2.54 
21 91.97 13.13 
G 
22 78.84 46.66 
51.4 23 32.18 2.67 
24 29.51 2.07 
H 
25 27.44 13.50 
27.44 26 13.94 9.55 
27 4.38 4.38 
 
 
It can be seen in TABLE II that there are 8 work stations, the 
total allocated time of each work station can not exceed the 
cycle time which is 55.92 second. 
 
G. Line Balancing Moodie Young Result 
 
In addition RPW method, there is also Moodie Young. 
This method consists of two phases. TABLE III is the result of 
the Moodie Young method. 
 
 
TABLE III. MOODIE YOUNG RESULT 
 
Stations Element Standard Time 
Total 
Time 
A 
7 10.12 
43.29 
8 9.85 
9 13.23 
10 2.74 
11 7.35 
B 
1 3.00 
55.86 
2 12.09 
3 6.48 
4 19.21 
5 12.30 
6 2.79 
C 
12 21.46 
55.75 
13 3.11 
14 23.31 
15 7.87 
D 
16 50.43 
54.47 17 2.54 
18 1.49 
E 
19 20.88 
36.55 20 2.54 
21 13.13 
F 
22 46.66 
51.40 23 2.67 
24 2.07 
G 
25 13.50 
27.44 26 9.55 
27 4.38 
 
TABLE III shows that there are 7 work stations, the total time 
of each work station can not exceed the cycle time which is 
55.92 second. 
 
H. Line Balancing New Bidirectional Result 
One new method was developed to solve the problems 
of the balance of the new line is bidirectional; the method is 
based with the concept of critical path method.   
Critical path is work elements that have slack value 0. 
From this experiement, work elements that have slack value 0 
are work element  7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 
20, 21, 22, 23, 24, 25, 26, 27. New Bidirectional method 
results can be seen in TABLE IV.  
 
TABLE IV. NEW BIDIRECTIONAL RESULT 
 
Work Station 
Work 
Element 
Standard 
Time 
Total Time 
( Second ) 
1 /  FS1 
7 10.1177 
43.2879 
8 9.84558 
9 13.2321 
10 2.74186 
11 7.3507 
2 / FS2 
12 21.4577 
55.7524 
13 3.1129 
14 23.3079 
15 7.87395 
3/FS3 
16 50.4293 
54.4674 17 2.54413 
18 1.494 
4/FS4 
19 20.88 
36.55 20 2.54 
21 13.13 
5/FS5 
22 46.66 
51.40 23 2.67 
24 2.07 
6/ FS7 
1 3.00066 
55.857 
2 12.0851 
3 6.47581 
4 19.2056 
5 12.2982 
6 2.79167 
7/ BS1 
25 13.5013 
27.4387 26 9.55465 
27 4.38279 
 
The work elements in permanent station from TABLE IV 
become work station. From the iteration, there are FS and BS. 
FS consist of work elements that is position in the critical path 
and BS consist of work elements that is position not in the 
critical path. And then the total time of FS ( T(FS)) and BS 
(T(BS)) must not more than the cycle time that needed. T(FS) 
and T(BS) can be use to calculate the slack time of FS ( Wf) 
and BS (Wb). If Wf ≤ Wb, work station FS will be permanent and 
viseversa. 
 
 
 
I. Line Balancing Method Comparison 
 
TABLE V. LINE BALANCING COMPARISON 
 
Indicator Current RPW Moodie Young 
New 
Bidirectional 
Line 
Efficiency 48.89 % 72.60 % 82.97 % 82.97 % 
Balance 
Delay 51.11 % 27.40 % 17.03 % 17.03 % 
Smoothest 
Index 95.81 49.06 36.88 36.88 
#Work 
Station 9 8 7 7 
 
It can be clearly seen from TABLE V that when the 
company implemented Moodie Young or New Bidirectional 
method, the line efficiency will increase from 48.89% to 
82.97%. The balance delay will be reduced from 51.11% to 
17.03%. The number of work stations will be reduced from 9 
stations to 7 stations, which means the number of labor 
required can also be reduced. 
 
V. CONCLUSIONS AND RECOMMENDATION 
 
A. Conclusions 
1. Based on the line balancing method comparison, the best 
methods are Moodie Young method or New 
Bidirectional method. The two methods can increase the 
line efficiency from 48.89% to 82.97%, reduce the 
balance delay from 51.11% to 17.03%, and reduce the 
number of work stations from 9 work stations to 7 work 
stations. 
2. Based on this research, it is possible to obtain a 
production target of 1,030.07 pieces of plastic bag per 
day. The time it takes to produce one piece of plastic bag 
is 55.92 seconds. 
 
B. Recommendations for Future Research 
In this study, researchers did not touch the aspects of the 
production layout. It is recommended for the company to 
conduct research on the production layout to further improve 
productivity and to enable better worker movement in the 
production facility. 
 
 
REFERENCES 
 
[1] J. Heizer and B. Render, Operations Management. New Jersey: Prentice 
Hall, 2011. 
[2] N. Kumar and D. Mahto, “Assembly  Line  Balancing:  A  Review  of 
Developments  and Trends in Approach to Industrial Application,” 
Global Journal of Researches (G), vol. 13(2), pp. 29-50, 2013. 
[3] M. Güner, Ö. Yücel, C. Ünal, ‘‘Applicability Of Different Line 
Balancing Methods In The Production Of Apparel,” Tekstil Ve 
Konfeksiyon, vol. 23(1), pp. 77-84, 2013. 
[4] S. Wignjosoebroto, Ergonomi Studi Gerak dan Waktu. Surabaya: Guna 
Widya, 2008. 
[5] A. Apriyono and A. Taman, “Analisis Overreaction Pada Saham 
Perusahaan Manufaktur Di Bursa Efek Indonesia (Bei) Periode 2005-
2009,” Jurnal Nomina, Vol. 2(2), 2013. 
[6] V.V. Pachghare and R. S. Dalu, “Assembly Line Balancing Methods–A 
Case Study,” International Journal of Science and Research, vol. 3(5), 
May 2014. 
[7] L. Gozali, L. Widodo and M. Bernhard, “Analisa Keseimbangan Lini 
Pada Departemen Chassis PT Toyota Motor Manufacturing Indonesia 
Dengan Algoritma Ant Colony, Rank Positional Weight, dan Algoritma 
Genetika,” Jurnal Teknik Industri, vol. 2(2), pp. 119-126, July 2012.   
[8] H. Kusuma, Manajemen Produksi. Yogyakarta: ANDI, 2009. 
[9] L. Natalia, S. Sinulingga and I. Siregar, “Penyeimbangan Lintasan Pada 
Perakitan Transformator Dengan Metode Moodie Young Dan Comsoal 
Pada PT. XYZ,” e-Jurnal Teknik Industri FT USU, vol. 3(4), pp. 35-52, 
November 2013. 
[10] S. Avikal, R. Jain, P.K. Mishra and H.C. Yadav, “A Heuristic Approach 
for U-Shaped Assembly Line Balancing to Improve Labor Productivity,” 
Computers and Industrial Engineering, vol. 64(4), pp. 895-901, April 
2013.
 
 
 


Improvement Of Production System Efficiency and Production Capacity Using Line Balancing Method

Heriyati, Pantri

Purchase Intention of Microinsurance: by Client Value or Trust?

Binus University

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