Innovative Line Balancing for the Aluminium Melting Process

This research article explores the optimization of aluminium extrusion processes through advanced line balancing techniques, focusing on maximizing marginal profit by increasing melting and casting outputs. By employing mixed integer linear programming (MILP), we identify strategies to minimize idle costs and enhance production efficiency. The study demonstrates that increasing the daily cycle rate from 2 to 4.36 cycles results in a significant rise in daily marginal profit, calculated at USD67,786, after accounting for additional labour costs. This optimization is achieved by expanding the workforce from 8 to 12 operators across two shifts, leading to a 50% increase in labour expenses. The findings reveal a remarkable 117.6% growth in marginal daily profit, underscoring the potential of automation and intelligent manufacturing in transforming the aluminium extrusion industry. Insights from cross-industry research, including Lean Methodology in the Modern Garment Industry, further illustrate the broader applicability of these advancements. This study highlights the critical role of automation in driving productivity and profitability in manufacturing sectors, paving the way for future innovations in aluminium extrusion and beyond.