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à Introduction
à Objectives
à Origin of line balancing
à Factors responsible for line balancing.
à Advantages and disadvantages.
à Termonology
à Important parameters
à Steps of generalized algorithm
à Different method of line balancing problem
à Kilbridge and wester heuristics
à Solved example
à Balance of line in variety of ways
à References
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à For smooth and efficient working of the assembly
line every work station should be assigned with
equal amount of work measured in terms of time
units, and this process of apportioning the
assembly work among the operators is known as
µassembly-line balancing¶.

à Line balancing is mainly associated with product

layout or flow shops.

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à To subdivide the station into several sub stations.
à Precedence relationships must be maintained
during allocating operations.
à To minimizes the total idle time.
à To optimize the congestion.
à It ensures that the stages of production are co-
ordinated and bottleneck are avoided.

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à Although the first assembly line was set up as early as
V V
.
à m
was the pioneer in starting the first
assembly line for car manufacturing.
à The line-balancing problem is probably the most
complicated problem faced by the engineer when
designing a production line.
à Recently this problem of µline balancing¶ has been
formulated analytically, and has drawn the attention of
those concerned with the science of management.

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à If finished product is the result of many sequential
problem.

à Difference in production capacity of different

machines.

à Cycle time required for workstation.

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ADVANTAGES
à Uniform rate of production.
à Less work-in-process.
à Easy production control.
à Effective use of facilities.
à Less bottle necking.

DISADVANTAGES
à More capital intensive.
à Low flexibility.
à Monotony of work for operators.

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à -orkstation
à Cycle time(C.T.)
Productive time period
C.T. =
Production volume per period

à -ork element
à Predecessor element
à Task time(t)- Standard time to perform
element task.
à Station time(T)- Total standard work content
of specific workstation.

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à Line efficiency (L.E.)
N

 
  ™ 
p
= =
  i=
 
    
    

à Balance delay (B.D.)

þ  =  p

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à Smoothness Index (S.I.)
 


S.I. = {Î( 
 
 
 ) }


If S.I. = „, means a perfect balance

k = total no of workstation<total no of element

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cycle time (C.T.),
precedence matrix,
total number of work elements(M),
work element times.

 unassigned cycle time(UACT) = CT,

station number (-S=)
total number of assigned work element(N)=

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) Print the station number(-S).
) Initialize the total number of assigned work element counter to one, i.e. i=.
) If the  th work element is not assigned and all immediate precedors of the 
th work element are assigned or no immediate precedors, then go to step ,
otherwise go to step .
) If the  th work element time is less than or equal to the unassigned cycle
time(UACT), then go to step, otherwise go to step.
) Include the  th work element in the list A.
) Increment the total number of assigned work elements counter by one, i.e. 
r A
) If  ” M, then go to step 
otherwise go to step .
) If the number of work elements in the list A is more than „,then go to step
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otherwise go to step .

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 ) Perform the following and then go to step .
a) Update UACT = CT
b) Update -S = -SA
c) Print -S
„) If the number of work element in the list A is equal to one, then assign that
work element to the current station
otherwise select a work element from
list A using a given HEURISTIC.
) Subtract the recently assigned work element time from UACT and print the
recently assigned work element¶s number.
) Update N =N A
) If N ” M, then go to step 
otherwise go to step 
 ) Compute B.D. in percentage.
) Stop.

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Element time

-ork element
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w p
    

 ! "
) Print the station number(-S).
- - 
) Initialize the total number of assigned work element counter to one, i.e. i=.
  
) If the  th work element is not assigned and all immediate precedors of the 
, 
th work element are assigned or no immediate precedors, then go to step ,
otherwise go to , step .  „
)) Perform thework
If the  th following- andtime
element thenisgo to step
less than .
or equal
- to the unassigned cycle

a)time(UACT),
Update UACT then= CT
,go to step, otherwise go to step. 
) b)Include
Updatethe-S =th-SA
work element in the list A.
,  
) c)Increment
Print -S the total number of assigned work elements counter by one, i.e. 
„) theA
If r number of work - element in the list A is equal
- to one, then assign that
) If  ”element
work M, thentogothe - current
to station
otherwise
step 
otherwise -select
go to step . a work element from
) listIf A using
the a given
number of  HEURISTIC.
work elements in the list A is more than „,then go to step

) Subtract the recently
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otherwise go to assigned
, ,„ step . work element „ time from UACT and print the 
recently assigned work element¶s number.
, ,  „
) Update N =N A
) If N ” M, then go to- step 
otherwise go to step -  
 ) Compute B.D. in , ,
percentage.  
) Stop. ,,  
, „
 - - 
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Element time

-ork element
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-S- -S- -S- -S-

-S-

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TIME (min)  „   
+

Line efficiency = ™

 = $
 
     $

= 3 34

 ) 8)
Smoothness index = {Î( 
 
 
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= { 567%567%567% 567%56*7 }
= ' )&

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þ -! 9=  p
60 33
 3
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!  567%567%567%567%56*7
$

!  45$87 

'$ '$4

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à Diamond star motor automobile manufacturing facility has achieved
balanced assembly lines through traditional analysis combined with a highly
automated material system.

à Sun micro system has expended production facility balances lines with a
more modular approach using torque conveyor to drive the material
handling system.

à At asheville, -estinghouse has five separate assembly lines balanced by

one common feeder mini plant and one master storeroom.

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à   !!"# $%&
m!%!4:9S. G Ponnambalam, P. Aravindan  and G.
Mogileeswar Naidu.

à !#"!'('!&)'!!"#
"%&*"# Christian Becker and Armin Scholl.

à '!&&''%&*"#
martand telsang.

à ('%'&*"#R. paneerselvam.

à +%&( $(%,&' $%&*"#

E.Falkenauer and A.Delchambre.

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