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In manufacturing industry , poor layout of assembly is considered to be major hurdle in increasing the productivity and efficiency .

Types of assembly line --1. Single model line 2. Batch model line 3. Mixed model line

Batch Model Line----

This line produces each model in batches.

Workstations are set up to produce required quantity of the first model then the stations are reconstructed to produce other model.

Problem statement---- 1. Organizing process flow 4. It’s more economical to use one assembly line to produce several products in batches than build a separate line for each model. . 2. Reducing the cycle time 3.Products are often assembled in batches when medium demand. Specify the no of workstations and workers. Propose a new layout of the trumpet assembly line.

Line Balancing Line balancing is commonly technique to solve problems occurred in assembly line. .

.Line balancing is a technique to minimize imbalance between workers and workloads in order to achieve required run rate. Products can’t move to other station if it doesn’t fulfill required task at that station. Line balancing operates under two conditions: i) Precedence Constraint. The aim is to maintain production at an equal rate. It shouldn’t across other station because certain part needs to be done before others. ii) Cycle time Restriction Cycle time is maximum time for products spend in every workstation.

Objective of Line Balancing Line balancing technique is used to: i) To manage the workloads among assemblers. Terminology for Line Balancing Minimum Rational Work Element .Different workstation has different cycle time. ii) To identify the location of bottleneck. iii) To determine number of workstation.

*Minimum rational work element is the smallest practical indivisible tasks into which the job can be divided. . Workstation Process Time *Work is preformed either manually or by some automatic device. screw and nut etc. Total Work Content *Total work. These work elements cannot be subdivided further *Example: drilling a hole. The work performed at station consists of one or more of the individual work elements. content is the aggregate of all the work elements to be done on the line. Twc. *Tej : where j is used to identify the element out of the ne elements that make up the total work.

E. . Cycle Time *Cycle time. is the ideal or theoretical cycle time of the flow line. *At efficiencies less than 100% the ideal cycle time must be reduced (or ideal production rate must be increased). Tc ≤E / Rp Where Rp is production rate. which is the time interval between parts coming off the line. *When consider efficiency. the ideal cycle time must be reduce.*Tsi: indicate the process time at station i of an n stations line. Tc.

Precedence Diagram *A graphical representation of the sequence of work elements as defined by the precedence constraints. the order in which the work elements can be accomplished is limited. the one with the largest value of Ts.* The minimum possible value of Tc is established by the bottleneck station. Balance Delay (Balancing Loss) . Tc ≥ max. Tsi Tc ≥ Tej Precedence Constraints *Technological sequencing requirements.

.*Balance delay is a measure of the line inefficiency which results from idle time due to imperfect allocation of work among station.