Production Line Balancing Optimization for Wire Harness Assembly Engineering

Miaosen Yu

doi:10.6919/ICJE.202511_11(11).0007

Authors

Miaosen Yu

DOI:

https://doi.org/10.6919/ICJE.202511_11(11).0007

Keywords:

Wire Harness Processing; Assembly Engineering; Industrial Engineering; Production Line Balancing; Bottleneck Processes.

Abstract

The rapid development of manufacturing has driven expansion in the automotive industry, placing wire harness manufacturers under dual pressure to enhance production efficiency and reduce costs. Addressing the challenges of low efficiency, uneven production rhythms, and prominent bottlenecks in wire harness assembly operations, this paper proposes a production line balancing method integrating industrial engineering theory with practical application techniques: Design and implement a Python-programmed wire navigation system to streamline wire positioning; Conduct 3D modeling of workstations to optimize layout and task area allocation; Evaluate the effectiveness of the optimization plan using metrics such as production line balancing rate and task duration. This research advances production line balancing in assembly engineering and offers practical reference value for the automotive wire harness manufacturing industry.

Downloads

Download data is not yet available.

References

[1] Liu Wen, Zhao Xiaoyang, Kang Siyu, et al. Analysis of Automotive Wiring Harness Layout and Reliability [J]. Automotive Practical Technology, 2018 (13): 55-56.

[2] Ying Luo, Yuan Zhiping. Introduction to Industrial Engineering. Beijing: China Science and Technology Press. 2020.

[3] Rasib A A, Abdullah R, Wahyono F Z, et al. Enhancing manufacturing efficiency: A case study on automotive assembly line balancing techniques for improving production capacity[J]. Journal of Engineering Science and Technology, 2025, 20(2): 427-441.

[4] Nguyen H G, Kuhn M, Franke J. Manufacturing automation for automotive wiring harnesses[J]. Procedia Cirp, 2021, 97: 379-384.

[5] Pitakaso R. Differential evolution algorithm for simple assembly line balancing type 1 (SALBP-1)[J]. Journal of Industrial and Production Engineering, 2015, 32(2): 104-114.

[6] Kumar R N, Mohan R, Gobinath N. Improvement in production line efficiency of hemming unit using line balancing techniques[J]. Materials Today: Proceedings,2021,46: 1459-1463.

[7] Castillo-Pérez V, Carrasco-Armendariz L, Corral-Chacón M, et al. Productive Process Improvement at Automotive Wire Harnesses Enterprise Through Work Teams[C]//International Conference on Applied Human Factors and Ergonomics. Cham: Springer International Publishing, 2019: 510-519.

[8] Roser C, Lorentzen K, Lenze D, et al. Bottleneck prediction using the active period method in combination with buffer inventories[C]//IFIP International Conference on Advances in Production Management Systems. Cham: Springer International Publishing, 2017: 374-381.

[9] Pirogov A, Gurevsky E, Rossi A, et al. Robust balancing of transfer lines with blocks of uncertain parallel tasks under fixed cycle time and space restrictions[J]. European Journal of Operational Research, 2021, 290(3): 946-955.

[10] Hienerth C, Lettl C. Exploring how peer communities enable lead user innovations to become standard equipment in the industry: Community pull effects[J]. Journal of Product Innovation Management, 2011, 28(s1): 175-195.

[11] Pei Fengque, Tong Yifei, Wang Yixiang, Li Dongbo. Analysis of Automotive Wire Harness Production Information and Layout Optimization [J]. Mechanical Design and Manufacturing Engineering, 2014, 43(12): 43-47.

[12] Zhang Na. Development of a Web-Based Automotive Wiring Harness Quality Inspection Management System [D]. Dalian University of Technology, 2018.

[13] Ding Chengbo, Liu Mi, Shi Jincheng, et al. Research on Deep Learning-Based Visual Defect Detection Technology for Wire Harness Terminals [J]. Wire & Cable,2023,66(2): 54-58.

[14] Wang Linqi, Xu Huijuan, Sun Wanxin, Zhang Wenzheng, Ding Jiawei. Application of Smart Display Screens in the Automotive Wiring Harness Industry [J]. Automotive Practical Technology, 2023, 48(05): 143-146.

[15] Liu Fei. Evaluation and Optimization of Production Line Balancing for Refrigerator Freezers at HR Company [Doctoral Dissertation]. Shandong University of Technology, 2022.

[16] Zuo Erbing. Design and Development of a Tube Terminal Feeding Device for Automotive Wiring Harnesses [J]. Internal Combustion Engines and Accessories, 2023(03):46-48.

[17] Gao Jingjing. Application of Work Study and Balancing Analysis in Automotive Air Conditioning Vent Assembly Lines [Doctoral Dissertation]. Shanghai: Shanghai Jiao Tong University, 2012.

[18] Zhang Cuizhu, Li Zhitao, et al. Production Line Balancing Optimization for P-Type Toys Based on Mixed-Integer Programming [J]. Electromechanical Engineering Technology, 2022, 51(05): 198-203.

[19] Zhang Suning. Research on Production Line Balancing and Visualization for Apparel Manufacturing Aimed at Management Informatization [D]. Tianjin University of Technology, 2021.

[20] Jiao Yuling, Deng Xue, Li Lin, et al. Bilateral U-shaped Assembly Line Balancing and Collaborative Optimization under Multiple Constraints [J]. Journal of Jilin University (Engineering Science), 2023, 53(7): 2053-2060.

[21] Zhang Wenyu. Research on Production Line Balancing Optimization for Product A at Company D [D]. Beijing Jiaotong University, 2022.

[22] Wang Xiyao. Research on Balanced Optimization of Company Y's Condenser Production Line Based on Lean Manufacturing [D]. Beijing Jiaotong University, 2022.

[23] Zou Yalan. Research on Production Line Balancing Optimization for TB Company Navigation Host Assembly [D]. China University of Mining and Technology, 2020.

[24] Sakka L, Sundararajah K, Kulkarni M. TreeFuser: a framework for analyzing and fusing general recursive tree traversals[J]. Proceedings of the ACM on Programming Languages, 2017, 1(OOPSLA): 1-30.

[25] Hernandez Gutierrez S. Solving Reasoning Problems with Large Language Models via Recursive Decomposition[J]. 2024.