A Project report on

“Assembly Line Balancing”

By

Ashok N. Mulinti
PGDM Operations
(MM 09-11310)

Under the guidance of

Sarvesh Raut
(Plant Manager, Assembly Line, MMM)

Submitted to

Balaji Institute of Modern Management, Pune

In partial fulfillment of the requirement for the award of

Post graduate diploma in management
(2009-2011)
 PREFACE

The MBA program is well structured and integrated course of business studies. In
every professional course training is an important factor. The main objective of
practical training is to develop skill in student by supplement to the theoretical
study of business management in general. Industrial training helps to gain real life
knowledge about the industrial environment and business practices.

Professors give us theoretical knowledge of various subjects in the college but we

practically exposed of such subjects when we get the training in the organization.

During the whole training we got a lot of experience and came to know about the
management practices in real that how it differs from those of theoretical
knowledge and the practically in the real life.

In today’s globalize world, where cutthroat competition is prevailing in the

market, theoretical knowledge is not sufficient. Beside this one need to have
practical knowledge, which would help an individual in carrier activities and it is
true that, “Experience is the Best Teacher”
 ACKNOWLEDGEMENT

With immense pleasure, I would like to present the project report for Magneti
Marelli Motherson (MMM) Auto System Ltd., Pune. It has been an enriching
experience for me to undergo my summer training at MMM which would not
have possible without the goodwill and support of the people around. As students
of Balaji Institute of Modern Management, Pune, I would like to express my
sincere thanks to all those who helped me during my practical training
programme.

I sincerely feel that the credit of this project cannot narrow down to one
individual. This work is an integrated effort of all those concerned, through whose
cooperation and guidance I could achieve its completion. I greatly indebted to
express profound gratitude to Mr. Sarvesh Raut (Plant Manager, Assembly Line,
MMM) and Mr. Vinod Patil (Deputy Manager, Assembly Line, MMML) for giving
me the opportunity and reposing confidence in my abilities by giving me the
freedom to work on the project independently at MMM and helped me at every
step whenever needed..
At last but not the least my grateful thanks to Prof, Col A. Balasubramanian,
President, Sri Balaji Society and Directress Dr. Seema Singh Zokarkar, BIMM, who
allowed me to do my project at MMM, and to all our faculty members for the
proper guidance and assistance extended by them. I also grateful to my parents
and friends to encourage & giving me moral support.

However, I accept the sole responsibility for any possible error of omission and
would be extremely grateful to the readers of this project report if they bring such
mistakes to my notices.
 DECLARATION

I hereby declare that the project work entitled “Assembly Line Balancing”
submitted to Balaji Institute of Modern Management, is a record of an original
work done by me under the guidance of Mr. Sarvesh Raut (Plant Manager,
Assembly Line, MMM), and this project work has not performed the basis for the
award of any other degree or diploma/associate ship/fellowship and similar
projects if any.
 Executive Summary

The automobile sector is one of the sectors that are experiencing an exponential
growth and same with the Auto components industry. With intense competition
the profit margins are under pressure. This has lead to strategic changes in
functioning of auto components companies. MMM has been in a pioneer in this
field by setting up & efficiently managing a highly efficient production system
for auto components specially in Light solution.

The project that we got has the objective to understand the line balancing for
the head lamp, tail lamp, pedal box assembly. The basic methodology of our
project includes understanding the waste in the current line, layout efficiency,
manpower assigned, etc.

After studying the current status different methodologies and theories are
applies to check the efficiency in the new improved system.
 Table of Content
Chapter 1 Introduction to Company 1

Chapter 2 Introduction to Project

2.1 Non Value Added Costs 8

2.2 Assembly Line Balancing 9

2.3 Assembly Line Principles 9

2.4 Objective of line balancing 10

2.5 Minimum Rational Work Element 10

2.6 Precedence Diagram 11

2.7 Assembly Cycle Time, Tc 11

2.8 Assembly Cycle Time Elements 12

2.9 Measures of Line Balance Efficiency 12

2.10 The Line Balancing Problem (LBP) 13

2.11 Line Balancing Constraints 14

2.12 Factors affecting Line Balancing & Problems Encountered 14

Chapter 3 Head Lamp Assembly

3.1 HL 310 18

3.2 HL D200 24

3.3 HL Xenon 31

3.4 Facts & Problems in the Head lamp assembly line 38

 3.5 Wastes in the Head Lamp Assembly 38

3.6 Solution implemented 39

Chapter 4 Pedal Box Assembly 41

Chapter 5 Tail Lamp Assembly

5.1 TL B517 53

5.2 TL 310 59

5.3 TL D200 64

5.4 Facts & Problems in the Tail lamp assembly line 70

5.5 Wastes in the Tail Lamp Assembly 71

5.6 Recommendations 71

Chapter 6 References 72