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The automotive sub-sector industries are experiencing obstacles during Covid-19 pandemic situation. One of the obvious problems is imbalanced production line due to out-of-control cycle time, whereby the cycle time difference is too sparse between workstations. This causes bottleneck and increase in overtime cost. To solve this problem, the Toyota Production System (TPS) and line balancing methods were applied to analyze and improve the production line. The initial analysis using TPS method shows minor improvement, whereby the line efficiency can be improved from 87.72% to 91.03%, balance delay can be reduced from 12.28% to 8.97%, and the smoothing index from 10.00 to 5.00 but the bottleneck problem still occurs. Then, further analysis using Helgeson Birnie line balancing method was applied resulted in a significant improvement with line efficiency 98.61%, balance delay 1.39%, and smoothing index 1.00. Simulation using promodel software shows there are 2173 quantity of finish goods can be produced in run time 890 minutes. [ABSTRACT FROM AUTHOR]