Research on Improvement of LED Lamp Production Line Based on FlexSim

Abstract

Addressing the core issues of low production line balance rate, severe idle human resources, and limited production capacity in a certain LED lamp assembly line, this study comprehensively employs the stopwatch time study method, the Westinghouse Rating System, and production line balancing theory to systematically diagnose the current state of the production line. Through work measurement, it identifies that the OP8 lamp board soldering station and the OP18 packaging station constitute a bimodal bottleneck. The original line's bottleneck cycle time reaches 43.089 seconds, the balance rate is only 49.65%, and the smoothness index is as high as 23.81, indicating severe "cycle time cliffs" and resource waste. Based on this, this paper proposes two differentiated improvement strategies: the efficiency-driven scheme (Scheme I) applies the ECRS principle to merge 18 workstations into 12. With no additional investment, it increases the balance rate to 74.48%, increases per capita output by over 50%, and achieves staff reduction and efficiency improvement. The capacity-expansion scheme (Scheme II), based on the Theory of Constraints, implements parallelization transformation for the bottleneck processes, compressing the cycle time to 21.545 seconds, raising the balance rate to 77.72%, reducing the smoothness index to 5.25, and doubling the theoretical single-shift capacity to 1,336 units. Finally, the FlexSim simulation software is used to dynamically verify the improvement schemes. The error between the simulated output and the theoretical calculation is controlled within 1%, confirming the effectiveness of the model and the robustness of the optimization schemes. This study indicates that enterprises can flexibly choose improvement paths based on their strategic phases of cost priority or scale priority, providing a reliable decision-making basis for lean production management.