Assemly Line Balancing

7/31/2019 Assemly Line Balancing

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Assembly Line Balancing


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Line balancing

The techniques employed for design of

product layouts is known as line balancing.

The layout design seeks to identify the

minimum no. of resources require to meet a

targeted production rate and the order inwhich these resources are to be arranged so

that the production process become smooth.


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Assembly Line Balancing

Analysis of production lines

Nearly equally divides work between

workstations while meeting requiredoutput

Objectives

Maximize efficiency

Minimize number of

work stations


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An Assembly Line Layout


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Line BalancingSome measures of interest

oductionDesiredActual

TimeAvailableTimeCycleDesiredActual

Pr)()(

TimeCycle

timestaskallofSumrequiredstationsworkofNoMinimum .

timeCyclensworkstatioofNumber

timestaskallofSumnUtilisatiosourceAverage

*Re


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A factory working in 2 shifts each of8 hours produces 24,000 electricbulbs using a set of workstations.

Using this information compute theactual cycle time of the plantoperation.

There are 8 tasks required to

manufacture the bulb. The sum of alltask times is equal to 12 seconds.How many workstations are requiredto maintain this level of production ifcombining of tasks into that many

workstations is a feasible alternative?

Example


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Solution to example

Available time = 2*8*60*60 = 57,600 seconds

Actual production = 24,000 electric bulbs

Therefore, using equation 8.2

Cycle time for each bulb is seconds

This means that the factory is producing a bulb every 2.4 seconds.

No. of work stations required =

Therefore the tasks are to be split among the five stations such that each

workstation will have sum of the task times to be 2.4 seconds.

4.2000,24

600,57

5

4.2

12


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Example of line balancingA computer manufacturer needs to design assembly stations in the

factory where the cabinet housing the hard disk, mother board and

other accessories is to be made. The factory currently works for one

shift of 8 hrs. The tasks, their duration and their precedence

relationships are given below:

Task Description Duration (in sec.) Precedence

A Assemble & position the base unit 70 -

B Install hard disk 80 A

C Install mother board 40 A

D Insert ports 20 A

E Install speaker 40 AF Connect relevant modules to disk 30 B,C

G Install controller 50 C

H Visually inspect & close with

a cover plate 50 D,E,F,G


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If the cycle time is 80 seconds, what will the daily

production of cabinets be?

If the desired production rate is 320 cabinets perday, what is the maximum permissible cycle time?

What I the maximum and minimum no. of

workstations required to maintain this daily

production rate?

Design an assembly setup with 5 workstations.


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Example

The Model J Wagon is to be assembled on a

conveyer belt.Five hundred wagons are

required per day is 420 minutes, and theassembly setups and times for the wagon

are given in table.

Find the balance that minimizes the no.ofworkstations, subject to cycle time and

precedence constraints.


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Task Duration Tasks must precede

A 45 -

B 11 A

C 9 B

D 50 -

E 15 DF 12 C

G 12 C

H 12 E

I 12 E

J 8 F,G,H,I

K 9 K

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Assemly Line Balancing