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Assemly Line Balancing

The document discusses line balancing techniques used to design efficient production layouts. Line balancing seeks to identify the minimum number of resources needed to meet a target production rate by optimally arranging the order of resources. It aims to maximize efficiency and minimize the number of workstations while equally dividing work between stations to meet required output. Measures of interest include cycle time, production rate, resource utilization, and number of workstations. Examples demonstrate how to calculate cycle time from given information and determine the minimum number of workstations needed to maintain a production level based on task times and cycle time.

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Archna Chaudhary
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743 views11 pages

Assemly Line Balancing

The document discusses line balancing techniques used to design efficient production layouts. Line balancing seeks to identify the minimum number of resources needed to meet a target production rate by optimally arranging the order of resources. It aims to maximize efficiency and minimize the number of workstations while equally dividing work between stations to meet required output. Measures of interest include cycle time, production rate, resource utilization, and number of workstations. Examples demonstrate how to calculate cycle time from given information and determine the minimum number of workstations needed to maintain a production level based on task times and cycle time.

Uploaded by

Archna Chaudhary
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Assembly Line Balancing

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 in which these resources are to be arranged so that the production process become smooth.

Assembly Line Balancing


Analysis of production lines Nearly equally divides work between workstations while meeting required output Objectives
Maximize efficiency Minimize number of work stations

An Assembly Line Layout

Some measures of interest


AvailableTime Actual ( Desired ) Cycle Time Actual ( Desired ) Pr oduction
Sum of all task times Minimum No. of work stations required Cycle Time
Sum of all task times Average Re source Utilisatio n Number of workstatio ns * Cycle time

Line Balancing

Example
A factory working in 2 shifts each of 8 hours produces 24,000 electric bulbs using a set of workstations. Using this information compute the actual cycle time of the plant operation.
There are 8 tasks required to manufacture the bulb. The sum of all task times is equal to 12 seconds. How many workstations are required to maintain this level of production if combining of tasks into that many workstations is a feasible alternative?

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

57,600 2.4 seconds 24,000

This means that the factory is producing a bulb every 2.4 seconds. 12 No. of work stations required = 5 2.4

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.

Example of line balancing


A 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 A F 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

If the cycle time is 80 seconds, what will the daily production of cabinets be? If the desired production rate is 320 cabinets per day, 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.

Example
The Model J Wagon is to be assembled on a conveyer belt.Five hundred wagons are required per day is 420 minutes, and the assembly setups and times for the wagon are given in table. Find the balance that minimizes the no.of workstations, subject to cycle time and precedence constraints.

Task A B C D E F G H I J K

Duration Tasks must precede 45 11 A 9 B 50 15 D 12 C 12 C 12 E 12 E 8 F,G,H,I 9 K

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