One of the issues found in small and medium industry is the poor layout design affecting its productivity
and line efficiency. In automotive industries, more attention should be given in improving assembly line
to increase productivity. This paper presents application of line balancing at the accelerator and brake
pedal assembly line at a small and medium automotive industry. Research methodology employed in
this study includes time study, visualising cycle time based on Yamazumi Chart, distribution of workload
on each workstation using line balancing based on the current takt time and re-layouting the assembly
line. All the proposed layouts are assessed using commercially available software, DELMIA Quest to
evaluate the robustness based on parameters such as fluctuation in demand, availability of the machine,
and operator capacity. Finally, the outputs presented include reduction in manpower, maximum utilisation
of manpower, as well as machine and minimum total production cost. This will lead to productivity
improvement of the assembly line.