Chapter 4

Manual Assembly Lines

3️⃣ Line Balancing Algorithms

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
Good to Know

• The objective in line balancing is to distribute the total workload on the • In each of the
algorithms, we assume
assembly line as evenly as possible among the workers. that the manning level
is one / workstation
• In Mathematical Terms: • Computer programs
have been written to
solve large-scale
assembly line
problems
or
Trainer

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
Good to Know

• In this section we consider several algorithms to solve the line balancing • These methods are
problem heuristic, meaning
they are based on
common sense and
experimentation
rather than
(2) The Kilbridge (3) The ranked mathematical
(1) The largest optimization.
and Wester positional
candidate rule
method weights method Trainer

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.1 Largest Candidate Rule
Good to Know

• According to the largest candidate rule, work elements are arranged in • These methods are
descending order based on their Tek values heuristic, meaning
they are based on
• The algorithm consists of the following steps: common sense and
experimentation
rather than
A) Assign elements to mathematical
the worker at the first
workstation by selecting C) Repeat steps A and B
optimization.
the first element that B) Proceed to the next for the other stations in
satisfies precedence station. turn until all elements Trainer
requirements have been assigned.
& Total Tek <= Ts;
Repeat from top again

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.1 Largest Candidate Rule
Good to Know

Example • These methods are

heuristic, meaning
1️⃣Data Table: they are based on
common sense and
experimentation
rather than
mathematical
optimization.
Trainer

Twc =4.0 min 🔵 Rp = 53.33 units/hr 🔵 Tc = 1.08 min 🔵 Ts = 1 min

(Refer to Page 93 )

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.1 Largest Candidate Rule
Good to Know

Example • These methods are

heuristic, meaning
2️⃣Sorted Data Table: they are based on
common sense and
experimentation
rather than
mathematical
optimization.
Trainer

Twc =4.0 min 🔵 Rp = 53.33 units/hr 🔵 Tc = 1.08 min 🔵 Ts = 1 min

(Refer to Page 93 )

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.1 Largest Candidate Rule
Good to Know

Example • These methods are

heuristic, meaning
3️⃣Assign to Workstations they are based on
common sense and
experimentation
rather than
mathematical
optimization.
Trainer

🔵 Eb = 0.8 🔵 d= 0.2

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.2 Kilbridge and Wester Method
Good to Know

• It is a heuristic procedure that selects work elements for assignment to • In general, the
Kilbridge and Wester
stations according to their position in the precedence diagram. method provides a
superior line balance
• In the Kilbridge and Wester method, work elements in the precedence solution than the
diagram are arranged into columns, as shown largest candidate
rule (although this is
not the case for our
example problem).

Trainer

❗If a given element can be located in more than

one column, then list all of the columns for that
element
❗Sort by Columns (Asc) ➔ Sort by Tek (Desc)

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.2 Kilbridge and Wester Method
Good to Know

• It is a heuristic procedure that selects work elements for assignment to • In general, the
Kilbridge and Wester
stations according to their position in the precedence diagram. method provides a
superior line balance
• In the Kilbridge and Wester method, work elements in the precedence solution than the
diagram are arranged into columns, as shown largest candidate
rule (although this is
not the case for our
example problem).

Trainer

❗If a given element can be located in more than ❗Element 3 Could not be selected for station 1, as it
one column, then list all of the columns for that will make station time >1
element
❗Sort by Columns (Asc) ➔ Sort by Tek (Desc)

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.3 Ranked Positional Weights Method
Good to Know

• In this method, a ranked positional weight • The ranked

value (call it RPW for short) is computed for positional weights
method was
each element. introduced by
Helgeson and
• The RPW takes into account both the Tek Birne, and it is
value and its position in the precedence sometimes
identified by their
diagram. names
• Specifically, RPWk is calculated by summing Trainer

Tek and all other times for elements that

follow Tek in the arrow chain of the
precedence diagram.

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic

 3️⃣ Line Balancing Algorithms
3.3 Ranked Positional Weights Method
Good to Know

• The ranked
positional weights
method was
introduced by
Helgeson and
Birne, and it is
sometimes
identified by their
names
Trainer

fb.com/kaizen.ar youtube.com/kaizenarabic @kaizenarabic kaizenarabic