Assembly Line Balancing

Assigning all tasks to a series of workstations so that each workstation is limited by

the cycle time and so that the unassigned or idle time across all workstations is minimized. Workload equalization is another important objective of the balance. Product interval time, time between products being completed at a workstation, also called takt time and cycle time. Task: is the smallest element of work; it can not be subdivided further. Workstation: is a place of work with workers, equipment and material to perform one or more tasks. Line: is made up of one or more workstations. Cycle Time (throughput time): the overall time to complete an individual product also the time it takes to assemble one unit or the time elapsed between two successive units coming off the line. Precedence Chart: a chart that specifies the order in which the tasks must be performed in the assembly process.

Line Balancing Steps

1. 2. Specify the sequential relationships among tasks using a precedence diagram. Calculate cycle time (C), using the following formula:

C
3.

Productive time per day (P)

Unit output per day (D)

Calculate the minimum theoretical number of workstations (Nt), using the following formula:

Nt =
4.

T, sum of task times

Select a primary rule by which tasks are to be assigned to workstations and a secondary rule to break up ties should they occur. Assign tasks to workstations according to specified rules. Evaluate efficiency (Eff.) and balance delay (BD) as follows:

5.

Eff. =

T Na * C

BD =

Sum of idle time Na * C

= 1 Eff.

Rebalance if eff. is low using a different primary rule.

Designing Line-Flow Layouts

Line Balancing: Assignment of work to stations in a line so as to achieve the desired output rate with smallest number of workstations There are two constraints in line balancing : 1. Precedence requirements
Physical restriction, order of operations

2. Cycle time restrictions

Max. operating time allowed for each workstation

Depend on demand rate, production time

Line Balancing Process

1. Draw and label a precedence diagram.
2. Calculate the desired cycle time required for the line. 3. Calculate the theoretical minimum number of workstations. 4. Group elements into workstations, recognizing cycle time and precedence constraints. 5. Calculate the efficiency of the line. 6. Stop if theoretical minimum number of workstations on an acceptable efficiency level reached. If not, go back to step 4.

Assembly Lines Balancing Concepts

Question: Suppose you load work into the three work stations below such that each will take the corresponding number of minutes as shown. What is the cycle time of this line?

Station 1
Minutes per Unit

Station 2
7

Station 3
3

Assembly Line Balancing Concept

Question: Suppose you load work into the three work stations below such that each will take the corresponding number of minutes as shown. What is the cycle time of this line?

Station 1
Minutes per Unit

Station 2 7

Station 3 3

Answer: The cycle time of the line is always determined by the work station taking the longest time. In this problem, the cycle time of the line is 7 minutes. There is also going to be idle time at the other two work stations.

Example of Line Balancing

Youve just been assigned the job a setting up an electric fan asbly line with following tasks:

Task A B C D E F G H

Time (Mins) 2 1 3.25 1.2 0.5 1 1 1.4

Description Assemble frame Mount switch Assemble motor housing Mount motor housing in frame Attach blade Assemble and attach safety grill Attach cord Test

Predecessors None A None A, C D E B F, G

Example of Line Balancing:

Precedence Diagram
Task Predecessors A None B A C None Task Predecessors E D F E G B

A, C
A B G

E, G

H E

Example of Line Balancing: Precedence Diagram

Question: Which process step defines the maximum rate of production? 2 A 1 B 1 G 1.4 H F 1

C 3.25

D 1.2

E .5

Example of Line Balancing: Cycle Time

Question: Suppose we want to assemble 100 fans per day. What would our cycle time have to be?

Example of Line Balancing: Number of Workstations

Question: What is the theoretical minimum number of workstations for this problem?

Example2 : Line Balancing

A company must produce 600 unit output in a 40-hour week. Given the following conditions, balance the assembly line
Work Element A B C D E F Precedence A B A, E C, D Performance Time (min) 1 2 2 4 3 4

Example3: Line Balancing

Additional Example
work elements, precedence reqmts and time reqmts to assemble a picture frame are shown here.

Elements
A B C D E F G H I

Description
Attach left frame side to top of frame Attach right frame side to bottom of frame Attach left and right frame subassemblies Cut 8-inch by 10-inch glass Cut 8-inch by 10-inch cardboard Place glass into frame Place cardboard into frame Secure cardboard and glass Apply descriptive label to glass

Precedenc e
A, B C, D E, F F, G D

Time (min)
0.35 0.35 0.70 0.50 0.50 0.20 0.20 0.50 0.10

1. 2. 3. 4. 5. 6.

Construct a precedence diagram of the process and label task times. Set up an assembly line capable of producing 1,600 frames per 40-hour week. Calculate the efficiency and balance delay of the line. Calculate the maximum number of frames that can be assembled each week. Rebalance the line for maximum production. Indicate the composition of each station. Assume the company can sell as many frames as can be produced. If workers are paid Rs8 an hour and the profit per frame is Rs5, should the production quota be set to the maximum? Assume one worker per station.

Example4: Line Balancing

Toy Wagon Assembly Line Balance Example
Task A Performance Time (sec.) 45 Tasks that must precede ---

B
C D E F G H I J K

11
9 50 15 12 12 12 12 8 9

A
B --D C C E E F,G,H,I J

Precedence Diagram
12 45 sec. 11 B 15 9 C 12 H 12 I F 8 9

A
50

12 G

Balance the Line Using Most Followers Rule

Task time(sec)
Task Remaining

time

Rem. Tasks

Feasible

most followers

Task @

longest opr. time

Task@

St. 1

45

5.4 idle

none

Balance the Line Using Most Followers Rule

Task time(sec)
Task Remaining

time

Rem. Tasks

Feasible

most followers

Task @

longest opr. time

Task@

St. 1 St. 2

A D

45 50

5.4 idle 0.4 idle

none none

Balance the Line Using Most Followers Rule

Task time(sec)
Task Remaining

time

Rem. Tasks

Feasible

most followers

Task @

longest opr. time

Task@

St. 1 St. 2

A D

45 50

5.4 idle 0.4 idle

none none

St. 3 B E

11 15

39.4 24.4

C, E C,H,I

C, E C

C
F*

9
12

15.4
3.4 idle

F,G,H,I
none

F,G,H,I

F,G,H,I

Balance the Line Using Most Followers Rule

Task time(sec)
Task Remaining

time

Rem. Tasks

Feasible

most followers

Task @

longest opr. time

Task@

St. 1 St. 2

A D

45 50

5.4 idle 0.4 idle

none none

St. 3 B E C St.4 F* G* H I J

11 15 9 12 12 12 12 8

39.4 24.4 15.4 3.4 idle 38.4 26.4 14.4 6.4 idle

C, E C,H,I F,G,H,I none H, I I J none

C, E C F,G,H,I H, I

E F,G,H,I H, I

Balance the Line Using Most Followers Rule

Task time(sec)
Task Remaining

time

Rem. Tasks

Feasible

most followers

Task @

longest opr. time

Task@

St. 1 St. 2

A D

45 50

5.4 idle 0.4 idle

none none

St. 3 B E C St. 4 F* G* H I J St. 5 K

11 15 9 12 12 12 12 8 9

39.4 24.4 15.4 3.4 idle 38.4 26.4 14.4 6.4 idle 41.4 idle

C, E C,H,I F,G,H,I none H, I I J none none

C, E C F,G,H,I H, I

E F,G,H,I H, I

Efficiency and Balance Delay Calculations

Efficiency =

195 (5) 50.4)

= 0.77 or 77%

Balance Delay =

57 (5) (50.4)

= 0.23 or 23%

Check, Total =
Notice that BD = 1.0 Eff.

100%