EA ZC412 / MM ZC412 / DM ZC412

FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

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Learning Objectives

 Analysis of Single-Model Assembly Lines

 Cycle Time
 Line Balancing Problem
 Line Balancing Algorithms

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Manual Assembly Line

• A production line consisting of a sequence of workstations

where assembly tasks are performed by human workers as
the product moves along the line
• Organized to produce a single product or a limited range of
products
 Each product consists of multiple components joined together by
various assembly work elements
• Total work content (Twc) - the sum of all work elements required to
assemble one product unit on the line

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Manual Assembly Line

Configuration of a manual assembly line with n

manually operated workstations

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Manual Assembly Line

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Line Balancing
 The process of equalizing the 𝐷𝑎
𝑅 𝑝=
amount of work at each 50 𝑆𝐻
workstation is called line
60 𝐸
balancing. 𝑇 𝑐=
Assembly-line balancing 𝑅𝑝
operates under two constraints:
• Precedence requirements
• Cycle time restrictions
 Maximum amount of time the
Rp = Hourly production rate, units/hour
product is allowed to spend at each
Da = Annual demand, units/year
work station, if targeted production S = .Number of shifts/week
H = hours/shift
rate is to be achieved. E = Line efficency 6
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Line Balancing

Min# of workstations Efficiency

𝑇 𝑤𝑐 𝑇 𝑤𝑐
𝑤= 𝐸 𝑏=
𝑇𝑐 𝑤 𝑇𝑠

Twc = work content time, min/pc

Tc = cycle time of the line, min/cycle
w = theoretical minimum number of workers.
Ts = maximum service time among all stations
Ts = Tc-Tr
Tr = repositioning losses
Eb = balance efficiency
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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Line balancing procedure

The various steps of line balancing are—

1. Draw and label a precedence diagram.
2. Calculate the cycle time required for the line.
3. Calculate the theoretical minimum number of workstations.
4. Calculate the service time against which the line must be
balanced.
5. Group elements into workstations, recognizing cycle time
and precedence constraints.
6. Calculate the efficiency of the line.
7. Determine if the theoretical minimum number of workstations
or an maximum efficiency level has been reached. If not, go
back to step 4.
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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Example

A small electrical appliance is to be produced on a single model

assembly line. The work Content of assembling the product has
been reduced to the work elements listed in Table . The table also
lists the standard times that have been established for each element
as well as the precedence order in which they must be performed.
The line is to he balanced for an annual demand of 100.000 unit/yr.
The line will operate 50 wk/yr, 5 shifts/wk. and 7.5 hr/shift.
Manning level will be one worker per station. Previous experience
suggests that the up time efficiency for the line will be 96%, and
repositioning time lost per cycle will be 0.08 min. Determine: (a)
total work content time (b) required hourly production rate Rp to
achieve the annual demand, (c) cycle time (d) theoretical minimum
number of workers required on the line, and (e) service time to which
the line must be balanced.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Example of Line Balancing
Problem

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Precedence Constraints

Restrictions on the order in which work elements can be

performed

Precedence
diagram

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Solution

Total work content time= Twc=4 min

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Line Balancing Algorithms

Largest Candidate Rule

 Assignment of work elements to stations based on amount of time
each work element requires
Kilbridge and Wester Method
 Assignment of work elements to stations based on position in the
precedence diagram
 Elements at front of diagram are assigned first
Ranked Positional Weights
 Combines the two preceding approaches by calculating an RPW
for each element

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Largest Candidate Rule
 Work elements are arranged in descending order according to
their Tek values.
1. Assign elements to the worker at the first workstation by
starting at the top of list and selecting the first element that
satisfies precedence requirements and does not cause the
total sum of Tek at that station to exceed the allowable Ts;
when an element is selected for assignment to the station,
start back at the top of the list for subsequent assignments.
2. When no more elements can be assigned without exceeding
Ts, then proceed to next station
3. Repeat steps 1 and 2 for as many additional stations as
necessary until all elements have been assigned.
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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Example of Line Balancing
Problem

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Precedence Constraints

Restrictions on the order in which work elements can be

performed

Precedence
diagram

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Largest Candidate Rule

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Largest Candidate Rule

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Largest Candidate Rule

Solution to line
balancing example:
(a) Assignment of work
elements
(b) Physical sequence
of stations with
assigned work
elements

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Kilbridge and Wester Method
 Assignment of work elements to stations based on position in
the precedence diagram.
1. Work elements in the precedence diagram are arranged into
columns. The columns can then be organized into a list
according to their columns, with the elements in the first
column listed first.
2. Elements in a given column are presented in the order of their
Tek value; that is the largest candidate rule has been applied
in each column.
3. Once the list is established, the same three step procedure is
used as before.

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Precedence Constraints

Restrictions on the order in which work elements can be

performed

Precedence
diagram

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Kilbridge and Wester Method

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Kilbridge and Wester Method

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Ranked Positional
Weights Method
1. A ranked positional value (RPW) is computed for each
element.
2. The RPW takes into account both the Tek value and its
position in the precedence diagram.
3. RPWk is calculated by summing Tek and all other times for
elements that follow Tek in the arrow chain of the precedence
diagram.
4. Elements are compiled into a list according to their RPW
value, and algorithm proceeds using the same three steps as
before.

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Precedence Constraints

Restrictions on the order in which work elements can be

performed

Precedence
diagram

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Ranked Positional
Weights Method

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Ranked Positional
Weights Method

E= 4 / (5 X 0.92 )= 86.95 %

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EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-16, 23/11/24 BITS Pilani, Pilani Campus
Thanks

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BITS Pilani, Pilani Campus