ASSEMBLY LINE

BALANCING
 Introduction
• The manufacturing assembly line balancing was
first introduced in the early 1900’s.
• There are different types of assembly line balancing
problems.
-SALBP-1.
-SALBP-2.
• Line and work cell balancing is an effective
tool to improve the throughput of assembly
lines
 What is Assembly Line
Balancing (ALB)?

• Assembly Line Balancing, or simply

Line Balancing (LB), is the problem of
assigning operations to workstations
along an assembly line, in such a way
that the assignment be optimal in some
sense.
• Goals of ALB:
-minimize number of work
stations.
-minimize the cycle time.
-minimize idle time.
-maximize the line efficiency.
Assembly line Principles:
• Division of labor principle.

• Interchangeable parts principle.

• Material workflow principle.

• Line pacing principle.

Types of ALB
• SALBP
• UALBP
• MALBP
• GALBP
What is the Takt Time?
• Takt time is most simply the average rate at
which customers buy products and hence
the rate at which products should be
manufactured.
• It is expressed in time units one every so
many minutes or so many minutes between
completions
Takt Time = Available Work Time
Customer Demand
Example:
Customer demand = 10 units / month
Total time available = 20 days
Takt time = 20
10
=2
Drumbeat = 1 part every 2 days
Each process needs to complete
one unit every 2 days
Benefits of the Takt time

• Easily managed processes

• Output of each process matches
customer demand
• Reduced costs
• Improved quality
Line Balancing : Simple Example
Improved Situation
 Minimum Work Stations:
• Calculate the theoretical minimum number of
workstations (N).
– If Cd = 4.8 minutes

 ti
j ti = completion time for
task i
i =1 j = number of tasks
N= Cd Cd = desired cycle time
 Line Efficiency:
• Evaluate the efficiency of the line (E).
– If Cd = 4 minutes and N = 4 work stations.

 ti
j ti = completion time for
task i
i =1 j = number of tasks
E=
Cd = actual cycle time
N Cd
N = actual number of
workstations
Conclusion:
• Simply Assembly Line Balancing is a
valid method to optimize assembly
lines. By using Takt search we can
easily optimize the ALB problems.
balanced assembly line help to increase
the productivity of organization.
References:

1. www.optimaldesign.com/Download/Opti Line
/FalkenauerPLM05.pdf
2. www.acsco.com/ LineBalancing .htm
3.http://www.manufacturinginstitute.co.uk/text.asp?
PageId=83
4.http://www.simcore.fr/Pages/en/en_soft_pplb.php?
Langue=en&IndexMnu=6