5.

7 Simple single-model lines design

3. Line balancing approach:

1956, Jackson poposed a simple LB technique as
following:
Determine all candidates – C1 (workelements) can
assign to 1st workstation.
In C1, determine all candidates – C2 can assign to 2nd
workstation;
In C2, determine all candidates – C3 can assign to 3rd
workstation;
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 30/81
5.7 Simple single-model lines design

3. Line balancing approach:

1956, Jackson poposed a simple LB technique as
following:
Continuing this process to balance, or all
workelements are assigned, i.e., getting minimum No.
of workstations within given cycle time.
This technique can apply for small size problem. But
large size one, we have to use computer softwares to
find solutions.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 31/81

5.7 Simple single-model lines design

3. Line balancing approach:

1. Kilbridge & Wester method

This is simple heuristic algorithm for LB problem.

Considering example such as: design a production
line including 21 workelements that showed in below
precedence relationship diagram.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 32/81

5.7 Simple single-model lines design

3. Line balancing approach:

I II III IV V VI VII VIII IX X XI
6 9 10
0 3 8

5 5 5
Processing time 16 19
4

5 4 5 2 5 12 10 15 6
4
1 5 9 11 12 13 14 15 17 20

10
5
18
6

8 6 6
2 7 10

precedence relationship diagram

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 33/81
5.7 Simple single-model lines design

3. Line balancing approach:

circle: work element;

Number in circle: the order/number of work element;

Number above circle: processing time respectively;

Roman number: column number including work

elements respectively;

Arrow direction: present precedence relationship of

respective work elements;
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 34/81
5.7 Simple single-model lines design
Table 5.1
Column Work Movable jobs Processing Column Cumulative
(a) element (b) (c) time (d) time (e) time (f)

0 6
I 1 5 19 19
2 8
3 III – V (with 8) 9
4 5
II 5 4 29 48
6 III 5
7 III – V (with 10) 6
8 IV – VI 10
III 9 5 21 69
10 IV – VI 6

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 35/81

5.7 Simple single-model lines design
Table 5.1 (cont.)
Column Work Movable jobs Processing Column Cumulative
(a) element (b) (c) time (d) time (e) time (f)
IV 11 2 2 71
V 12 5 5 76
VI 13 4 4 80
VII 14 12 12 92
VIII 15 10 10 102
16 5
IX 17 X 15 30 132
18 X 10
X 19 5 5 137
XI 20 6 6 143
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 36/81
5.7 Simple single-model lines design

3. Line balancing approach:

Assumption that given cycle time TC = 36. LB steps as followings:

S1: find out any cumulative time in column (f) (table 5.1) that equals 36. If
not go to step 2.

S2: select the largest cumulative time in column (f) less than 36, in this
case, it is 19 (respecttively column I in precedence relationship diagram).

S3: determine the additional time of this station is 17 (minus 19 from 36)

S4: considering workelements in column II that have total completion time

less than or equal 17. In this example, the total completion time is 16
(including jobs 4, 6, 7.), and the total workstation time is 35.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 37/81

5.7 Simple single-model lines design

3. Line balancing approach:

Assumption that given cycle time TC = 36. LB steps as followings:
S5: select the smallest cumulative time in column (f) greater than 36, in this
case, it is 48 (respectively column I, II in precedence relationship diagram).
S6: consider any workelements (in column I & II) that can move to next
columns. In this case, job 3 (with job 8) & job 6 can move out and total
station time is 34.
S7: select the next cumulative time in column (f), total time is 69
(respectively column I, II, & III).
S8: consider any workelements (in column I, II & III) that can move to next
columns (station time ≤ 36). In this case, job 3 (with job 8) and job 7 (with
job 10) can move out & total station time is 38 (greater than 36) reject.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 38/81

5.7 Simple single-model lines design

3. Line balancing approach:

Assumption that given cycle time TC = 36. LB steps as followings:

S9: select continously the next cumulative time in column (f) (greater than
69) to reduce total station time to 36. In these cases, the station can not
improve.

S10: determine station 1 from all feasible alternatives, in this case, we

select alternative in step 4, and station time is 35 respectively.

S11: rewritten table 5.1 by deleting all assigned jobs in station 1. Calcultate
cumulative time in column (f) again, we develop table 5.2.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 39/81

5.7 Simple single-model lines design
Table 5.2
Column Work element Movable jobs Processing Column Cumulative
(a) (b) (c) time (d) tine (e) time (f)

0 6
1 5
2 Station 1 8 (35)
4 5
6 5
7 6
3 IV – V (with 8) 9
III 9 5 24 24
5 4
10 IV – VI 6
IV 8 V – VI 10 12 36
11 2
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 40/81
5.7 Simple single-model lines design
Table 5.2 (cont.)
Column Work Movable jobs Processing Column Cumulativ
(a) element (b) (c) time (d) tine (e) e time (f)
V 12 5 5 41
VI 13 4 4 45
VII 14 12 12 57
VIII 15 10 10 67
16 X 5
IX 17 X 15 30 97
18 10
X 19 5 5 102
XI 20 6 6 108

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 41/81

5.7 Simple single-model lines design

3. Line balancing approach:

Assumption that given cycle time TC = 36. LB steps as followings:

S12: find out any cumulative time in column (f) (table 5.2) that equals 36.
the cumulative time is 36 (including all jobs in columns III & IV, table 5.2)

S13: assign all jobs in columns III & IV to station 2, develop table 5.3.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 42/81

table 5.3

Column Work Movable jobs Processing Column Cumulative

(a) element (b) (c) time (d) tine (e) time (f)

0 6
1 5
2 Station 1 8 (35)
4 5
6 5
7 6
3 9
9 5
5 Station 2 4 (36)
10 6
8 10
11 2

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 43/81

table 5.3 (tt)

Column Work element Movable jobs Processing Column Cumulative

(a) (b) (c) time (d) tine (e) time (f)
V 12 5 5 5
VI 13 4 4 9
VII 14 12 12 21
VIII 15 10 10 31
16 X 5
IX 17 X 15 30 61
18 10
X 19 5 5 66
XI 20 6 6 72

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 44/81

5.7 Simple single-model lines design

3. Line balancing approach:

Assumption that given cycle time TC = 36. LB steps as followings:

S14: find out any cumulative time in column (f) (table 5.3) that equals 36. If
not go to step 15.

S15: select the largest cumulative time in column (f) less than 36, in this
case, it is 31 (respecttively column V, VI, VII, and VIII in precedence
relationship diagram).

S16: determine the additional time of this station is 5 (minus 31 from 36).

S17: considering workelements in next columns that have total completion

time less than or equal 5. In this example, the total completion time is 5
(including job 16), and the total workstation time is 36.

S18: assign job 16 into this station and develop table 5.4
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 45/81
Table 5.4

Column Work Movable jobs Processing Column Cumulative

(a) element (b) (c) time (d) tine (e) time (f)

0 6
1 5
2 Station 1 8 (35)
4 5
6 5
7 6
3 9
9 5
5 Station 2 4 (36)
10 6
8 10
11 2

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 46/81

Table 5.4 (tt)

Column Work element Movable jobs Processing Column Cumulative

(a) (b) (c) time (d) tine (e) time (f)
12 5
13 4
14 Station 3 12 (36)

15 10
16 5
IX 17 X 15 25 25
18 X 10
X 19 5 5 30
XI 20 6 6 36

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 47/81

5.7 Simple single-model lines design

3. Line balancing approach:

Assumption that given cycle time TC = 36. LB steps as followings:

S19: similarly, consider the cumulative time in column (f) (table 5.4) that
equals 36. In this example, all rest columns (IX, X, XI) are assigned, and
total station time is 36.

S20: assigned all the rest jobs into the last station (including jobs: 17, 18,
19, 20).

Therefore, all workelements are assigned (including 21 jobs), and balance

loss can be calculated as follows:

L% = (4x36 – 143)/(4x36)x100% = 0.69%

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 48/81

5.7 Simple single-model lines design

3. Line balancing approach:

Remarks:

1. The interchangeable columns (including jobs) helps to select jobs that

have relevant processing times to assign. Moreover, the movable jobs are
easily to assign, in the other words, the solution is more improvement.

2. The general solutions of type 1 LB problems is not unique. Except all

stations are full capacities (station time = cycle time). The assigned jobs to
stations, that are from any columns in precedence relationship diagram, can
be interchangeable. Therefore, supervisor can delay job-sequences that do
not affect to the balance in optimal solutions.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 49/81

5.7 Simple single-model lines design

3. Line balancing approach:

Remarks:

3. If posible, longer processing time jobs prefer to assign to shorter ones.

For instance, we assign one job with 20’ (processing time) before assign 2
jobs with 10’. Because two 10’-jobs are flexible for assigning and
interchanging.

4. Besides, all movable jobs easily assign to certain stations.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 50/81

5.7 Simple single-model lines design
Stations diagram
6 9 10
0 3 8

5 5 5
16 19
4

5 4 5 2 5 12 10 15 6
4
1 5 9 11 12 13 14 15 17 20

10
5
6
18

8 6 6
2 7 10

Station 1 Station 2 Station 3 Station 4

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 51/81

5.7 Simple single-model lines design

3. Line balancing approach:

2. Ranked positional weights – r.p.w:

Helgeson và Birnie (1961) developed this algorithm at

General Electric ltd.Co. (in USA). This algorithm
provides solutions quickly & accurately, consider
other example as follows:

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 52/81

5.7 Simple single-model lines design

3. Line balancing approach:

2. Ranked positional weights – r.p.w:

Processing
0.05 time
7

0.32 0.20 0.23 0.20 0.32 0.10 0.30

0 2 5 6 8 9 10

0.10 0.05 0.10

1 3 4 Work element

Precedence relationship diagram

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 53/81
5.7 Simple single-model lines design
0.05
7

0.32 0.20 0.23 0.20 0.32 0.10 0.30

0 2 5 6 8 9 10

0.10 0.05 0.10

1 3 4 p.w(0) = job 0 (= 0.32)
+ job 2 (= 0.20)
Determine weight of certain job as + job 5 (= 0.23)
follows: plus processing time of this job + job 6 (= 0.20)
with all following jobs in precedence + job 7 (= 0.05)
relationship. + job 8 (= 0.32)
+ job 9 (= 0.10)
Ex: determine weight of job 0 such as:
+ job 10 (= 0.30) = 1.72
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 54/81
5.7 Simple single-model lines design
Similarity for the rest jobs, establish the table 5.5 for
ranked positional weights of all work elements.
Jobs Processing time Positional weight (p.w)
0 0.32 1.72
1 0.10 1.65
2 0.20 1.40
3 0.05 0.87
4 0.10 0.82
5 0.23 1.20
6 0.20 0.92
7 0.05 0.45
8 0.32 0.72
9 0.10 0.40
10 0.30 0.30
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 55/81
5.7 Simple single-model lines design

3. Line balancing approach:

2. Ranked positional weights – r.p.w:

These weights reflex the size of jobs/elements & their

position.

Suppose that we develop a line for this problem with

given cycle time TC = 0.55;

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 56/81

5.7 Simple single-model lines design

3. Line balancing approach:

2. Ranked positional weights – r.p.w:
Combine table 5.5 and precedence relationship
diagram to complete table 5.6 with reduction r.p.w as
follow:
Jobs 0 1 2 5 6 3 4 8 7 9 10 Tổng

Processing time 0.32 0.10 0.20 0.23 0.20 0.05 0.10 0.32 0.05 0.10 0.30 1.97

weights 1.72 1.65 1.40 1.20 0.92 0.87 0.82 0.72 0.45 0.40 0.30

Direct 0, 1 2 5 1 3 4, 6 5 7, 8 9

precedence
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 57/81
5.7 Simple single-model lines design

According to this algorithm, we assign job to

workstation based on reduction of r.p.w (table 5.6),
but assigned jobs must satisfy precedence
relationship constraint.

Therefore, job 0 is asigned firstly, then we calculate

remained time of WS that is considered as time
constraint for assign next jobs until can not assign
any jobs.

Similarity for the rest WSs, we finish table 5.7.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 58/81

Jobs 0 1 2 5 6 3 4 8 7 9 10 Total
Processing time 0.32 0.10 0.20 0.23 0.20 0.05 0.10 0.32 0.05 0.10 0.30 1.97

Weights 1.72 1.65 1.40 1.20 0.92 0.87 0.82 0.72 0.45 0.40 0.30

Direct pre. 0,1 2 5 1 3 4,6 5 7,8 9

WS. Jobs Ready jobs Processing Cumulative Remain

0, 1 time time time

0 1 0.32 0.32 0.23

I 1 2, 3 0.10 0.42 0.13
3 2, 4 0.05 0.47 0.08

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 59/81

Jobs 2 5 6 4 8 7 9 10 Total
Processing time 0.20 0.23 0.20 0.10 0.32 0.05 0.10 0.30 1.97

Weights 1.40 1.20 0.92 0.82 0.72 0.45 0.40 0.30

Direct pre. 2 5 4,6 5 7,8 9

WS. Jobs Ready jobs Processing Cumulative Remain

2, 4 time time time

2 4, 5 0.20 0.20 0.35

II 5 4, 6, 7 0.23 0.43 0.12
4 6, 7 0.10 0.53 0.02

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 60/81

Jobs 6 8 7 9 10 Total
Processing time 0.20 0.32 0.05 0.10 0.30 1.97

Weights 0.92 0.72 0.45 0.40 0.30

Direct pre. 6 7,8 9

WS. Jobs Ready jobs Processing Cumulative Remain

6, 7 time time time

6 7, 8 0.20 0.20 0.35

III
8 7 0.32 0.52 0.03

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 61/81

Jobs 7 9 10 Total
Processing time 0.05 0.10 0.30 1.97

Weights 0.45 0.40 0.30

Direct pre. 7 9

WS. Jobs Ready jobs Processing Cumulative Remain

7 time time time

7 9 0.05 0.05 0.50

IV 9 10 0.10 0.15 0.40
10 0.30 0.45 0.10

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 62/81

WS. Jobs Ready jobs Processing Cumulative Remain
time time time
0 1 0.32 0.32 0.23
I 1 2, 3 0.10 0.42 0.13
3 2, 4 0.05 0.47 0.08
2 4, 5 0.20 0.20 0.35
II 5 4, 6, 7 0.23 0.43 0.12
4 6, 7 0.10 0.53 0.02
III 6 7, 8 0.20 0.20 0.35
8 7 0.32 0.52 0.03
7 9 0.05 0.05 0.50
IV 9 10 0.10 0.15 0.40
10 0.30 0.45 0.10
TC = 0.55 The percentage of balance loss L = 10.4%
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 63/81
5.7 Simple single-model lines design

3. Line balancing approach:

3. Largest candidate rule

The assigned jobs rule of this technique as follows:

Begining with WS1, select & locate the largest
processing time jobs (in available jobs set).

We apply this technique for previous example as

below:
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 64/81
5.7 Simple single-model lines design

3. Line balancing approach:

3. Largest candidate rule

Processing
0.05 time
7

0.32 0.20 0.23 0.20 0.32 0.10 0.30

0 2 5 6 8 9 10

0.10 0.05 0.10

1 3 4 Work element

Precedence relationship diagram

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 65/81
5.7 Simple single-model lines design

3. Line balancing approach:

3. Largest candidate rule

Considering WS 1:

There are only 2 available jobs for assignment (job 0 & 1). Job
0 has the longer processing time, then Job 0 is assigned. At
that time, we have only one available job (job 1) and it is
assigned. Now, job 2 & 3 are available, but job 3 is only
feasible because remain time is 0.13 and job 3 is assigned to
WS1 & this WS time is 0.47. ( open WS2)

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 66/81

5.7 Simple single-model lines design

3. Line balancing approach:

3. Largest candidate rule

Considering WS 2:

Now, Jobs 2 & 4 are available. Job 2 has priority to assign

besause of larger processing time. Jobs 4 & 5 are available,
but job 5 is assigned. At that time, jobs 4 & 7 are feasible
(because processing time of job 6 is over remain time - 0.12) &
job 4 is assigned WS time is 0.53 ( open WS3)

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 67/81

5.7 Simple single-model lines design

3. Line balancing approach:

3. Largest candidate rule

Considering WS 3:

Similarity, we assign jobs 6, 8 to WS 3 & total WS time is 0.52

Considering WS 4:

Similarity, jobs 7, 9, 10 are the last jobs for assigning to WS 4

and total WS time is 0.45

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 68/81

 0.05
7

0.32 0.20 0.23 0.20 0.32 0.10 0.30

0 2 5 6 8 9 10

0.10 0.05 0.10

1 3 4

WS. Jobs Ready jobs Processing Cumulative Remain

0, 1 time time time

0 1 0.32 0.32 0.23

I 1 2, 3 0.10 0.42 0.13
3 2, 4 0.05 0.47 0.08
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 69/81
 0.05
7

0.20 0.23 0.20 0.32 0.10 0.30

2 5 6 8 9 10

0.10
4

WS. Jobs Ready jobs Processing Cumulative Remain

2, 4 time time time

2 4, 5 0.20 0.20 0.35

II 5 4, 6, 7 0.23 0.43 0.12
4 6, 7 0.10 0.53 0.02
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 70/81
 0.05
7

0.20 0.32 0.10 0.30

6 8 9 10

WS. Jobs Ready jobs Processing Cumulative Remain

6, 7 time time time

6 7, 8 0.20 0.20 0.35

III
8 7 0.32 0.52 0.03

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 71/81

 0.05
7

0.10 0.30
9 10

WS. Jobs Ready jobs Processing Cumulative Remain

7 time time time

7 9 0.05 0.05 0.50

IV 9 10 0.10 0.15 0.40
10 0.30 0.45 0.10

With small size problems, this technique provides faster solution than r.p.w.
technique. However, with large size ones, this technique has trouble
because of local optimum.
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 72/81
WS. Jobs Ready jobs Processing Cumulative Remain
time time time
0 1 0.32 0.32 0.23
I 1 2, 3 0.10 0.42 0.13
3 2, 4 0.05 0.47 0.08
2 4, 5 0.20 0.20 0.35
II 5 4, 6, 7 0.23 0.43 0.12
4 6, 7 0.10 0.53 0.02
III 6 7, 8 0.20 0.20 0.35
8 7 0.32 0.52 0.03
7 9 0.05 0.05 0.50
IV 9 10 0.10 0.15 0.40
10 0.30 0.45 0.10
TC = 0.55 The percentage of balance loss L = 10.4%
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 73/81
5.7 Simple single-model lines design

3. Line balancing approach:

4. Cycle time modification

The above techniques design production lines with given cycle

time. In general, the minimum number of WSs is equivalent
the minimum percentage of balance loss.

Example in the above problem with 11 jobs, the balance loss is

10.4% with 4 WSs solution, and given cycle time is 0.55. In
realistic, WS 3 has the lognest total processing time is 0.53
and the cycle time can reduce to 0.53. At that time, the
percentage of balance loss is only 7%. If we continue to
reduce cycle time then number of WS is increased.
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 74/81
5.7 Simple single-model lines design

4. Some improvement techniques for LB problems:

1. Improved work methods: reduce processing time of jobs

2. Changed machining speeds: relevant to automated lines

(transfer lines)

3. Increased operator performance: when bottle-neck accurs

we can increase operator performance for improving
solution.
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 75/81
5.7 Simple single-model lines design

4. Some improvement techniques for LB problems:

4. Diversion of excess items: changing WIP/components if

necessary

5. The movement of workers: moving or changing workers if

necessary.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 76/81

5.7 Simple single-model lines design

5. Some support techniques for LB problems:

1. Parallel workstations or additional workers:

a. Use extra time (over time, under time,…)

b. Add more similar workstations if necessary.

c. Use additional workers at bottle-neck WS.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 77/81

5.7 Simple single-model lines design

5. Some support techniques for LB problems:

2. Cycle time less than processing time:

In this situation, we apply the above a, b, c cases reduce

cycle time get expected volume easily. We can assign
jobs to get solutions easily.

In realistic, we can use some extra workers who help bottle-

neck WS if necessary, or re-arrange jobs to get balance
solutions.

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 78/81

5.7 Simple single-model lines design

5. Some support techniques for LB problems:

3. Division of work elements:

Work elements can be broken down to improve balance

solutions. Example we can drill 2 holes at 2 separated WSs
to reduce WS time (WS time is increased if we drill at the
same WS).

Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 79/81

5.7 Simple single-model lines design

6. Location of quality inspection in flow lines:

1. Locate quality inspection (QI) before high operational cost

WS to avoid high quality cost from this WS.

2. Locate QI before some consecutive WSs which are difficult

to control and inspect.

3. Locate QI after WS that has high defective rate.

4. Locate QI before WS with previous defective WIPs are

difficult to detect (such as painting or assembly process)
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 80/81
5.7 Simple single-model lines design

6. Location of quality inspection in flow lines:

5. Locate QI before WS where defective WIPs can not return to

rework.

6. Locate QI before WS with defective WIPs maybe occurred.

7. Locate QI before area where responsibilities are transferred

to next stages, example before assembly process, or
transfering to next stages to continue processing …
Lecturer: Đường Võ Hùng\Manufacturing system\Chapter 5: Mass manufacturing system 81/81