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FPA Lec6

Line Balancing Problem

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8 views8 pages

FPA Lec6

Line Balancing Problem

Uploaded by

maa43
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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3/29/2020

Fayoum University
Faculty of Engineering
Mechanical Engineering Department

FACILITIES PLANNING
Lec_6: Line Balancing Problem

Mohammed Abdelghany
Assistant Lecturer – Mechanical Engineering Department
E-mail/ [email protected]
Tel./ 002 – 01144876702

Types of Plant Layouts

1. Process layout

2. Product layout

3. Group layout

4. Fixed position layout

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Product Layout
• A product layout arranges machines in a line according
to the operations sequence that need to be performed
to assemble a particular product.

Eng/ M. Abdelghany 3

Designing Product Layouts


• Objective: to balance the assembly line.
• If each workstation on the assembly line takes the same
amount of time to perform the work elements that have
been assigned, then products will move successively from
workstation to workstation with no need for a product to
wait or a worker to be idle.

Workstation_1 Workstation_2 Workstation_3 Workstation_4

Eng/ M. Abdelghany 4

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Assembly Line Balancing


• Assigning tasks to a series of workstations so that idle time
is minimized.

• Grouping tasks into workstations.

• Trying to equalize the amount of work at each workstation.

Workstation_1 Workstation_2 Workstation_3 Workstation_4


5 minutes 5 minutes 5 minutes 5 minutes
1 2 3 4 5 6 7 8

Eng/ M. Abdelghany 5

Definitions
• Flow time; is the time required to complete an item (pass
completely through all stations of the line).
• Cycle time (Takt time):
• Time between unit coming off the end of an assembly line.
• The maximum amount of time the product is allowed to spend at each
workstation.

Eng/ M. Abdelghany 6

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Line Balancing steps


1) Draw a precedence diagram
• Precedence requirements: are Physical restrictions on the
order in which operations are performed on the assembly line

Eng/ M. Abdelghany 7

Line Balancing steps


2) Calculate the desired cycle time

• Desired cycle time:

• Ex. Suppose a company wanted to produce 120


units in an 8-hour day.

Eng/ M. Abdelghany 8

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Line Balancing steps


3) Calculate theoretical minimum number of workstations

4) Group elements into workstations

• Taking into account the desired cycle time and


precedence constraints.

Eng/ M. Abdelghany 9

Line Balancing steps


5) Calculate the efficiency of the line

• Line efficiency:

• Balance delay; is the total idle time of the line.

= (1 – efficiency)

6) Decide if an acceptable efficiency level has been reached


If not, go back to step 4 (Group elements into workstations)
Eng/ M. Abdelghany 10

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Assembly Line Balancing example


Real Fruit Snack Strips are made from a mixture of dried fruit, food
coloring, preservatives, and glucose. The mixture is pressed out into a thin
sheet, imprinted with various shapes, rolled, and packaged. The
precedence and time requirements for each step in the assembly process
are given below. To meet demand, Real Fruit needs to produce 6000 fruit
strips every 40-hour week. Design an assembly line with the fewest
number of workstations that will achieve the production quota without
violating precedence constraints.

Eng/ M. Abdelghany 11

Example solution

#1 Precedence diagram

Eng/ M. Abdelghany 12

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Example solution
#2 • Desired cycle time

#3 • Theoretical minimum number of workstations

Eng/ M. Abdelghany 13

Example solution
#4 • To balance the line, we must group elements into
workstations so that the sum of the element times
at each workstation is less than or equal to the
desired cycle time of 0.4 minute.

Station Task Task time Time left Task ready


1 A 0.1 0.3 B,C
B 0.2 0.1 C
2 C 0.4 0 D
3 D 0.3 0.1 None
Eng/ M. Abdelghany 14

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Example solution
• Assembly-line diagram:

#5
• Assembly-line efficiency:

Eng/ M. Abdelghany 15

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