<![CDATA[Assembly line imbalance is a significant issue in the manufacturing of complex products, often resulting in bottlenecks, idle time, and efficiency losses. This study integrates the Ranked Positional Weight (RPW) method with the Theory of Constraints (TOC) using the Drum–Buffer–Rope (DBR) mechanism to improve the performance of the sub-assembly line for an APC 6×6 engine and transmission. The analysis involved 39 work elements across eight stations, processed through standard time measurement, cycle-time calculation, and workstation formation using RPW. The balancing results show a reduction in stations from eight to four, leading to a twofold improvement in line efficiency—from 37.47% to 74.94%—along with a decrease in balance delay from 62.53% to 25.06% and a smoother workload distribution (smoothness index reduced from 695.66 to 486.58). The integration of TOC–DBR ensured a controlled production rhythm based on the capacity of the Critical Constraint Resource (CCR), with a 25% protective buffer to maintain flow continuity. Backward scheduling determined job release timing, aligning throughput with actual capacity. These findings confirm that combining RPW and TOC–DBR effectively enhances both assembly-line efficiency and the realism of production scheduling.]]>
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