382 no nu me ne as nus 116 Chap. 12 J AuematicWetfeston sn Data Capture ‘Whats aasponde: le RFID? What the erence betwen apse agenda acne ag? ‘What ate the relative avantges of RFID ove ba codes? What ae the reaive avanagesof barcodes ner FID? ‘What ae the resons why metic stripes are not widely weed it fSctory Moor operations? Whit isthe dsentage of opie carat secgaiton technology ever Bar ends reckon? What icin ppcaton ol shine vison in ins? PART IV Manufacturing Systems Chapter 13 Overview of Manufacturing Systems (CHAPTER CONTENTS 121 Component Manacing Sytem 1211 Proton Machines 1812 Material Handing Sytem 4313. Computer Cott System 3314 Human Resources 182 Types of Menofecuring Systms 1321 TypesofOperatons 1322 Number of Workstation and Systm Layout 1323. Levelof Automation 1324. Syston Flocbity 1825. Clssfcaton of Manufacturing Systems ‘This part ofthe book consider how automation and material bang technlogies, = vel as haman workers, are combined to create manufacturing systems. A manufactaring system is defined ws ealletion of intogrted equipment and human resoarees, whose function isto perform axe o more procesing andoc assembly operations ona starting ‘a material prt, rset of pss. The integrate equipment inlads production machines and tool material handling and work positioning deves, nd computer ystems. Human resouroes are requized eter fll ime or peiecally to keep the system rumning, The ‘manufacturing system is where the valu-sdéed work i accomplished onthe pars and ‘products. The poston of the manufacturing system inthe larger production systomn i shown in Figure 1.1.‘Chap. 13 / Oveviw of Manufacturing Systemg Tanicaig singe sens Earp ali cout mene ‘aateasad | [Maul ending csorttsnbges|[andidetcan {ef Misia cae Reo ine! Nang pene Figure 131 The peson of the manufacturing system in the larger protion system, ‘The present chapter provides an oveview of the various types of manufactering systems by describing their common components and features. A framework i thea 1), ‘The numberof workstations in the manufacturing system sa convenient ease ofits size. As the number of stations creases, the amount of work that canbe atom. plished bythe system increases It stands to reason that two workstations can accompli twice the workload of one station, Thus, one obvious elatonship is thatthe workload capacity of « manufacturing system increases in proportion to the number of worst, tions init 1m addition, there must be @syneeistic benefit obisined from multiple stations ‘working together rather than individually oherwisa it makes mote senso fr the tations to work independently. The synergisic benefit is uually derived from the fot tht the {otal amount of work performed on the part or products too complex to accomplish st 2 single workstation. There isjust too much work to perform atone stati. BY break ing the total work content down ico tasks, and assigning diferent aks o diferent ta- tions, the workloud at cach sation i simplified, The differet stations can be designed ‘o specaiein their own assigned tasks. They are therefore highly efficient. This is what ‘provides a mulistation system with ts synergistic benefit. Because ofthe specialization ‘designed ino cach station in mulistation system, such asjstem is able to del wih produc complesty beter than the same number of singe stations that esch performs ‘the total work entent onthe pastor product. The resus ahigher production rate for complex part and products. Autcmobie fsa assembly plants ilutrate this advantage. ‘The Local work content to assemble each car is typically 15-20 fr—too much time and too much complet for one workstation to cope with. However, when the orl work contents divided int simple tasks of bout I-min duration, ad these tasks axe signed to individual workers at stations along the line of flow, cars are produced atthe rate of shout 60 per hot. ‘More stations also mean the sytem is mare complex aad therefore more difelt to manage and mintain. It consists of more workers, more machines, and mere pats being handled The material banding ystems more complex in a mulation system. It ‘becomes increasingly complex asm increases. The logistic and coordination ofthe stem are more involved. Reiablty problems occur more frequently oa ‘Closely related to the umber af workstations isthe way te multiple statons are {aid out, Workstation layouts organized for fixed routing ate wally aranged inesey, asin production lie, while layouts organized for variable routing can have many por: sible configuration. The layout f stations isan important factor in determining the most appropriate material handling system, as indicated in Table 3.1. 1823. Level of Automation ‘The level of automation ofthe workstations i another factor that charctries 8 man facturing system, Inversely coreated with evtemstin level is the meaning level ‘ofa workstation, symbolized Mf, which tthe proportion of time that a worker spends atthe station, If.Mj = 1 for station jit means that one worker must beat the station 0, 1221 Types of Mnutacuring Systems a ‘contiavousy. Ione worker tends four automatic machines then Mf; = 0.25 foreach of the four machines assuming each machine requires the same amount of atertion, On sections of atemobile and tuck final assembly ines, many lations a.. ciel by mx tile workers, ia which case, = 2or 3 or moe. In general, high values of MM, ‘ngizate manual operation tthe workstation, wile low vluos (Mj < 1} denots some orm of automation. ‘The average manning evel ofa multstation manufacturing system faust in ‘alr ofthe diet Iabor conteat ofthe system. Iis defined as (3) where A = average manning level forthe sytem, ng = numberof utity workers as signed to the system: w; = number of workers asigned specifically to station i, for s2eo.-s;andW = total numberof workers assigned tothe sem, Uiliy workers are workers who ate aot signed to spec workstations instead they perform functions ‘such as (1) reliving workers t stations for personal reds, (2) maintenance and repair, (@) material handling, an (tol changing. Even 2 fully automated malistation system, i key to have utility workers who ae responsible fo Keeping it runing ‘There are wo basileves of automation adits approximate inverse, manning level, for workstatinsin a manufacturing system (1) manned workstations and 2) automsted workstations Manned workstations cons of production machines that are manually op- ‘rated or semiautomated. Both categories require a worker tobe in attendance daring ‘each and every work cycle. As meationed eal, in some cases one worker may beable to attend more than one machine (eg. a machine cuter, dsessed i Seton 14.4.2) if the semiautomatic yee long relative tothe serve required eoch cyl by the worker. ‘An sutomsed workstation is centered by 2 fully automated machine in which @ worker ie not rage to be presnt daring ich eye. Proc attetin hy a weer fe ‘commonly reqied fr purpores of maintenance, loading and unloading of parts, nso on. ‘The automaton level of the workstations in a manufacturing sem defines the level of autematon ofthe sytem isl. In most cases, this means that the system is ‘manned or automated. However, some mukistatio systems consist of some stations that are manned while others are fully automated. hiss refered to as partially automated or bybeid tem. 13.24. System Flexibility “The fourth ator that characeies a manufacturing system i the degre to wich it is capable of dating wih variations inthe pars or prods it produces, Erampies of pose dierences and vations hats manuatsiag system may have to cope with Sncude (1) starting materia, (2) sie and weight of the work ust, 3) pat geometry, (4) part oc yeu complex, and) optional featsesin an assembled prc. lecbilty B the cael tha allows a manufacturing stem to eng wil cain eel of vai tania pro roduc ste without nerapon x prodasion for haageores between rodel, Flat isgncaly 2 desirable fcoture of a manufactring stem. Systems tbat potest ae called flexible manfacing steno flebleasenbly ystems, o& sinilar names. They in produce dierent parr ase sls, or they ean realy ‘adapt onew sys when the previous ones become obsoleteChap. 13 / Overview of Manufacturing Systm In order tobe Mesibe, a manufacturing system must be able to perform the folio, ing functions every work eye: + Hienifcation of diferent work unis Different part cr produc styles requite dite ent operations The manutacoring system must identify the work unit in oder to pesform the covtect operations. In a manually operated or semiautomatic system, this task is usually an easy ene forthe workers). In an automated system, some ‘means of aucomatie work unt ientfaton must be devise ‘Quick changeover of operating insructions. The instructions, oF pact program in the ease of eemputerconoled praduetion machines, must correspond tothe cor et operation forthe given pat. Inthe case of a manually operate sytem, this ‘generally means workers who (1) ate skilled inthe variety of operations needed wo processor assemble the diferent work uit sys, and 2) know which operations to perform on each work wit syle. In semiautomatic and fully automated systems t ‘means that he required pat program seal avaiable tothe conrcller once the ‘work unit has been identified, ‘Quick changeover of physica sep. Plexi in manufaccring means that the di ferent wok units are not produce in hatches. To enable diferent work unitstyes tobe produced with no ine lost between one unit and the next, the esble manu facturing system must be capable of making any necessary changes in fsturng and tooling in very shor time (he changeover time should corespond approximately to te time required to exchange the competed work unit forthe next unit 0 be procesed) ‘These capabilies are often dificlt to engineer. In manually operated manuf. ‘uring syste, human errors can cause problems, such as workers nt pesforming the cextest operation onthe diferent part sys or omitting steps during assembly ofthe product, In automated systems, sensor systems must be designed to enable work unit ‘dontifistion. Part program carngeover is eccomplished with lative ease using today’s comapater technology. Changing the physical setups often the most challenging problem, snd ic becomes moe diffoult ax part or product variety increases. Endowing a man facturing sytem with exiilityiereases its complexity. The mseral handing item andlor pallet fstares mast be designed (o hold a variety of part shapes. The required umber of diferent tools insreases. Inspection becomes mote complicated Decatse of pat vatey. The logis of supplying the system with th corset quantities of different stating work parts fs more invohed. Schedling and eoordiating the sytem become! more difficul 1825 Classification of Manufacturing Systems Summarizing the preceding discussion, three basic ypes of manufacturing sjstens ean be identi: (1) single-staton cls, (2) rulttation systems with fied routing, and (@)nulstations)stems with varisle routing Esch typecanbeimplemented asa manned system oran automated ester, a depicted in Figure 133. I the cae of multistation s- ‘toms, hybrids consisin of mansed and atomnted stations are aso possible Singlo-Station Cals. Applications of singlsttion cells are widespread. The \ypical ease sa worker-machine cell Two categories ate distinguished: (1) mined ce, 510 182 /Typosof Manutacring Systems 363 : iene pean ‘al |_[ roan _[xeaar— | obetecee tg |_| [ion ‘ene Pee |_| asm ec ne aie somting [Netian| lee a LF nates Figure 183 Clasifction of manufacturing eytems in which a worker must be present ech work eyes nd (2) automated els, in which pe riodi attention is required les frequently than every cyl. In either case these ystems are used for processing aswell as assembly operations. Examples of single station cells include the flowing + Werke operating on epi late analy operated mache) + Wesker lading end kang a CNClathe eitonated mshne) * Weld and fier woking in a arcing operation (manly opted equipaen) + ENC ting cater th part carousel operating unatended sings obo oad and unload parts (fully automated machine). Single tation ool are described in Chapter 4. This type of manufacturing system is popular boas (1) ts the eases and east expensive manufacturing system 0 imple- ‘ment, especialy the manned version; (2) tis argably the most adaptable, adjustable, and Fexibe manufacturing system; and (3) a manned single workstation canbe converted to an automated station if demand forthe parts or products made in the station justi this [Maitistation Systems with Fixed Routing. A mulation manuictaring 9 tem with Gxed routing isa production line, which consis ofa seres of workstations Iaid out so thatthe work unit moves from one station tothe next, anda portion of the total work content i pcformed on it at each tation Transfer of work unis from one station tothe noi ually aecomplished by 2 conveyor or other mechanical transport‘Sha. 131 Overvinw of Manutoturing Systems ‘stem. However, in some cases the wok is simply pushed between stati ; Prodction ines are generally associate Iv applied in batch production. Bamps of the following 08 by band +h mass production, although they can ako ilitstion systems with fied routing inca {Manually neta proves sal per tol (manlly praled werkt) + Machining transfer line (avomstedworkstat * Automated asembly machine wit mated workstation) * Agemoble inlay ann wish may of th spot wen nd sy Feintng operations are automated while general asenly is aanual toe, system), 8 carousel system for work transport aut, Manual production lines wal pert asembly operations, and manal assent Eby fis ate dics in Chaper 5, Astomated lines perfnm etc pocesing SORRY Operations. The two types are dtc in Chaps 16 and I? There oy ube systems whic both manual and auiomatd sation ext in he sane ne Te ‘ase is analyzed in Section 1724 for assembly systems Jiutistation Systems with Variable Routing. A muliplestation sytem with Fable routing is goup of workstations organized to prodace a lnted range of ane Free t ive a masiam production eantts (pill 10012000 unis enous) The Feacusin parr produ sys mean diferencsin operations and sequences lope, tions hat mest be ertormed The sytem must posses ei incerta cope mh hy ‘ave Examples of mute station ste wih var osting inlet along * Manned machine cl designed to produce a family of pasts wih nia geometie features (manualy operated machines) * Renble manutscturng stem with wvorel CNC machin tccls ened by an uomaied conveyer system and operating under computer vont (atomsted ‘workstations, {A rows. RB “Operation Papi yi On te Way” Marfacing Engin, March 1997p. 06-12 EL Grooves MP. Pandata of Madera Monyouing Matrial, Process and Stems, Sede, Joba Wey & Sons ae, Hoboken, N30 B51 Greet MP and. Main, “Tene nMaucig Sten Design” Pein Fall Confrenos, Nth, TN, November 187 review Questions ‘REVIEW QUESTIONS 1 a 133 Ba Bs Bs a7 a ne 0 ma Ba no Whatisa mcufcaig ten? "Nan the four cnposents fa anfietrng tem. ‘What are dv lasiitins of rduction machines nes of worker puttin? Wat ae the ve tri banding uncins hat ast be prove as matting system? ‘What she dees baveen fed og snd vase routing in mmuicrng + ‘ens consisting of muliple wakes? Wat isa pale fue in work tensor a banaue sen? ‘A computer sem isa inter component ia moder mnufcusing tem. Nae fost ote eg fasion ofthe compute system ited tee, ‘Wat arte four fctors that canbe wed to dngish manufacturing yer inthe cs seston see ropes inthe chaps ‘hy is maming lvl inversely coneated with automation vel in & manuactng sysom?| ‘Whats eat ina mautstaing ste ‘Wiat are tbe tre cpsiss that manuteing stm mut poses is od tobe fesie? ‘Kame he bas catgois of manufacturing system they ar ened the tent. ‘What isa pret tine?se. 141 / Single Station Mennod Cole 357 is a a posed el (= 1). Chapter 14 |_[ Sistcones |_zaie ) ‘Seperaion |_| 5 oda ts esos cxcer ae) Single-Station sean —T Biases Manufacturing Cells Figure 141 Classifcation scheme or snge station manucturing cals, incing peal manning eel), 141 SINGLE-STATION MANNED CELLS ‘CHAPTER CONTENTS 11 Single Staton Manned Cots 2 Single Staton Autereted Cols 1421 Enables fr Unattended Cal Opertion 14.22 Parts Storage and Automate Pats Transfer "423 ONC Machining Cercers and Related Machine Tools 143 Appleatione of Single Station Call 1a Anaiyss of Single Station Calle ‘W441 Number of Workstations Reqd 1.42 Machine Cstors Single stations constitute the most common manufacturing sytem in industry, The} “ ‘operate independently of other workstations in the factory although thei acts are coordinated within the larger procuction system. Single-station manufacturing cll can bbe manned or automated. They are used fr processing and assembly operations. They ‘can be designed for production situations in whch all parts or products ate identical, for batch production where diferent part styles are made in batches, ofr production ia which different parts are made sequentially not in batches ‘This chapter describes the features and operations of single-station manufacturing cells, Figure 141 shows one paste lasification scheme. Two analysis issues elated 19 single-station cel are also examined (1) how many workstations are needed to satisfy production requirements and (2) how many machines can be assigned to one worker in ‘amochine cluster? A machine clusters collection of two cr more identical ar sinilar ‘machines that ae servied by one worker. “The sigle-station mtnned cl the standard model for which is one machine tended by cone worker, is probably the most widely used production method toy. It dominates job Shop prodvcton and betch production, and it snot uacommon even in high production, ‘Thee are many reasons for is widespread adoption, «+ Terequites the shortest mount oftime foimg}Sinet. The user company can quickly Tanch production of anew pt or product ung one or more manual workstation, hile plans end designs amore automated production method + Tustlly ees the east capital invesimect among altemative manufacturing seems. + Technologically itis the esis sytem to install and operate, an its maintenance requirements ae usualy minimal. + For many stations, particulary for low quantities of production, it resus inthe owes cast per unit produced. Tn geooral it isthe most flexible manufacturing system with regard to changoovers from one pat or produc sy to the next In one-achinefone- worker sation, the machine is manually operated or smi tomated na manually operated station, the operator controls te machine and oats and unloads the work. A typical processing example sa worker operating a standard machine tool sock as an engine lth, cil press or forge hanuner. The work sce equ the aten- tion of the worker either continuously ox fr most ofthe cpl (et opeator might relax ‘temporarily dung he eee whon the eed ic engaged on alate o dl pres) ha semiautomated sation, te machine i conrolled by some fonm of program, such ‘asa prt program that controls CNC machine too ring a portion ofthe work ee, and ‘the worker's function is to load and ualoed the machine ech cycle and psiccally change368 | hep. 14 Single Station Monutectuing Cts cattng tools In this cee, the work's -ttendanoe a tho station sroquired every Wark eee, although th worker’ attention may not be continuously ocupied throughout the eee, ‘Thete are several alternatives tothe standard model of one-machinelone- worker, Fis, the single ttn manned cel neues the case of a worker using hand tol (eg, screnriver and wrench in meckanical assembly) or portale powered tol (e8, pow. ‘ered handheld dil, soldering ion, or ae welding gun). Some manval inspection tas ko fall int this etegory. The key factor is thatthe worker pecforms the task atone locaton (one workstation inthe G01. ‘A second alesnative is when two or more workers are needed the machine or accomplish the tsk atthe workplace, Examples include: + Two workers required to manipulate heavy Forgings in forge prs + Avwolder and fier working in an ar-welding operation + Moltiste workers combining thelr efforts to assemble one large pice of machinery ata sngle assembly stati. A third varison from he standard eas is when there sa principal production ma chine, plus other equipment in the tation that supports the principal machine. The other ‘equipment i clearly subordinate to the main machine. Examples of clearly subordinate ‘equipment incide: + Dying equipment used to dry the plastic molding compound prior to molding ia a manually operated injection molding machine +A trinder used at an injection moléing machine to grind the sprues and runners ftom plasticmoldings for recytng + Trining shears used in conjuction wit a forge haramer to trim fash from the forgings. Fal, there at sitions in which the portion of the werk ee when the workers ‘byt much tha the portion af the cyl taken by homachine. When his our it ay ’e feasible toasign more than one machine tothe wotke, This he eae refered to asa ‘machin cluster i he copter introduction, Is decribed ore completely in Section 1442. 142. SINGLE STATION AUTOMATED CELLS ae ‘The single-ttion automated cell consis ofa fully automated machine capable of un attended operation fora time period loger than one machine eyele. A worker i nat equied tobe atthe machine except pecodicaly to lad and unload parts or otherwise teat Advantages ofthis system include the following: + Labor cost isreduce compared tote single station manned cell, + Among automated manufsctring systoms he single-staton automated eel iste casiest an least expensive syste: to implemen, + Production rates are usually igh than fora comparable manned machine. 4 Tr often represents the frst step toward implementing an integrated musa tion automated system. The uscrcompaay can install and debug the singe cut mated machines individually, and subsequently integrate them (1) electronically by mean of «supervisory compute system andlor (2) physically by means of an 16142 / Single Station Automated Cals m9 axon sil ning sen, Real he atm igo fram Section 1.4.3. eal ‘The sue of supporting equipment arses in single sation automated cells jas sit oes in mand singe station els, Examples of supporting equipment in automated cells indlud: + A fully automated injction-molding machine that ues drying equipment for the plastic molding compound. The dying equipment leary plays a supporting role to ‘he molding machin, + A robot loading and unloading an automated production machine, The produe- tion machine isthe principal machine inthe eel, andthe robot pays a supporting role + CAC Hathe with chip conveyor fo remove chips rom the ctting tea The chip eon: ‘eyor isthe supporting equipment, + Bow! feeders and other parts feeding devices used to deliver components in a singl-robot assembly cell Jn this case, the assembly robo isthe principal pro- uction machine nthe cell, and the parts feeders are supperting 142.1 Enablers for Unattended Cell Operation ‘Ackey feature of single saton automated cellists capably to operate unattended for extended periods of tie. The enablers tht provide tis capability ier depending on wether the system is designed 1 produce identical work units (no product variety) or Aitterent work snits (sot product vit). Enablers for Unatiended Production of lentical Work Units. The chica a tributes required for unatended operation of aaoniste ells designe for Merial pars ‘or products are the flloning: + Programmed eee tat allows tho machine to perform every step ofthe processing orasembly ce automaticaly. + Pantstorage system and a supply of parts tet permit continuous operation beyond one machine eee. The storage sytem must he capable of holding both raw work pats and completed work units, so two storage units are sometinesrequized, one focthe starting work parts andthe second forthe completed pat + Automatic rasfer of work pars between the sorage system andthe machine (a= ‘omaticunleading of frished pars fom the mache and loadag of raw work pats tothe machine). This transfers step in the regular work eyce. The parsonage stem andsutomatitranste of pats re discussed in amore detilin Section 1422, + Periodic atention of a worker who resupplies aw work pars, takes avay finished pars, changes tools as they wear out (depending on the process), and performs other machine fending fonctions that are necessary forthe particular pooesing or sembly operation © Buil-in safeguards that protect the sytem agalstopersing conditions that may be (1) unsafe to worker, (2) self-destructive, or (3) destructive to the wark units being processed or assembled. Some ofthese safeguards may simply be in the form of very high process aed equipment reliability, In other cases, the cell mus e fut- ished withthe capability for eror detection and eeovey (Sesion 423).(Chap. 14/ Single-Staton Manufocturing Cle Enables for Unattended Production of Different Work Units. The preceding ls of technical tributes also applies to cells designed for product variety. Additonal enablers are bo required fr thes cel: + Work idnifcatin system that can ditnguish between the diferent starting work ‘nits entering the sation, so thatthe correct processing Sequence can be used for that part or produt style. his may take the form of Sensors that recognize the features ofthe work unt o it may consist of automatic identification methods (Chapter 12) ln some casts, dential stating work unit are subjected to diferent processing operations according to 8 specified production schedule Ifthe starting units are identical a work part identifetion systems unnecessary. Program downloading capability to transfer the machine ele program correspond: ing tothe identified pat or product syle. This assumes that programs have been prepared in advance for all part syes, and that these programs are stored inthe rackine control uit or thatthe contol unit has aes to thee + Quick seup changeover capability so thatthe necessary work-holding devices snd ‘other oak foreach part are avilable on demand ‘The same enablers described here are aso required forthe uastended operation of ‘workstations in mutstation flexible manufacturing systems (Chapter 19). 14.22 Parts Storage and Automatic Parts Transfer “The partsstorage system and automatic transfer of pats between the storage system and the processing Station ae necessary tributes ofan automate cl that operates unt- tended fr extended periods of time. The storage sytem has a partsstorage capaci me Accordingly, the cell can theoretically operate uealtonded for length of time given by Sn (at) ‘ete UT = unattended time of operation ofthe manatactrng el min = ge tine for part) that is held in the parsstorge sytem, f0F j='1,2,~ho aed ‘y= aber ofp that an be stored, ps Ts ecution asues tat one work was ‘roesed each jl al ofthe parts ar dental and requ the ame machine jel, {hens equation ines the following: E UT = mle, a) In reality, the wateaed tne of operation wil be somentit es than ts amount (hy ane or more eyes), beat he worker needs ne 1 unlead he bed ples nd oad searing work uns into he storage system Capacties of part-storge systems ange from one pat to hundreds, AS Equation (142) indates, the ine of unattended operation increases dety wih storage capacity, so the storage sytem soul be designed with uficienl capacity “atsysome objective ofthe pan. Among the possible objectives are the fllowig: u + To provide enough time to allow a wotker to tend multiple machines «To provide aime interval equal tothe time between scheduled co changes, so tooling ‘canbe changed during the same machine downtine required fr changing pats + Toprovide atime terval equal to one complete sift 20.142 1 Single-Station Aut mated Cals m + To':chieve overnight operation, sometimes refered to as ighs-out operation that is tokexp the machines ranting when no workers arin the plat during the middle andlor night shit. Storage Capacty of One Par.» The minimum storage capacity of a parts storage system i one work part. Tn machining this cate is represeted by ato poston sttomads ple changer (APC), whith’ wed to exchange pallet fares between the machine toot workable and the manually operated onload pot son The mek parts ar imped and lated onthe ple Furs, stat hen he pal fire ssurasiy posioned in fon ofthe spindle, te pat its ce ‘ately located for procesing. igure M2 spews an APC sep fer anal ureaing tnd loading of pats. } ‘When te storage capaci sony ne pr ths wally cons thatthe worker mst be in attendance a the mashin fol ms. While the machine processing one work par he woke uniating the ices she nding thnx nrk probe rossi Ts ian improvement verso slorge copa, m niche th proven rochne ot eng uli dag vbading ae odin If = machine proven time and 7, = worker sre time (to oro uloding sn ein) te he veal eye tie he sig station wth o Sarge Lekth (183) By contrast, the overall eye time fora single station with one part storage capacity, 2, in gure 142, 6 T= MasTm.T) + sa) eiccine pemecange Figue 142 Aviomati pallet changr integrated wih 2 CNC besizcntal machining center (HMC) with minus uncading and oadng of work parts. At the completion ‘ofthe machining eye, the pallet curren tthe spindles moved oat the acmatic pallet changer (APC), andthe APC table is rtated 180° 1 move the other pallet into ‘aston for transfer tothe machine tool worktable. The HMCis shown here without itssafety enclosure(hep, 14 / Single Staton Manufacturing Cols Ove a fer adie Figure 43 Single station machining cllinterate wih an automated pallet storage and handling sistem. Key IR machine = storage retrieval mache, where 7, = the repositioning ime to move the completed part away fom the processing headend move the raw work pst into postin in rot ofthe wosk head, Fn most instances, the workerservie time is ss han the machine pressing ine, and machine wilzation is igh 17, > Ty the machine experiences forced time daring each work ee and this ‘undesirable, Methods analysis should be applied to reduce 7,0 that Z, < Ty ‘Storage Capactias Greater than One. Largersorage capacities alow unattended ‘operation, a long a loading and unloading the pars canbe accomplished ina reasonable time, Figure 143 depict ingle-tation machining colinteroced wih an automated pallet ‘storage and handling stem. Pars are stored on pli fintres and tanterced bya dedi ‘ited storagetetrioval machino (Secon 11.3.1) tothe machine tol for proesing (e, ‘ENC machining ceter, Section 1423). A commercially avalable system of tis type is called the Flexible Pallet Container (FPC), bilby Fastems (9). The FPC canbe designe {or vatous storage capacities end canbe coanerted toa varity of machine tool types._j ‘Figure 144 shows several posible designs of parsorage systems for CNC machining center. The partstocage units inefaced wih an automatic pallet changer, shutle cat, oF ‘other mechanism ta inteaed ietly withthe mechie tol. Comparable arrangements ‘ate avable for tring canter in which a industrial robot is omcnly used to perfor, Toad and unloading bexwoon the machine too nd the prt storage system. Pallet Extres ‘are no employed: nsead, the robot wes speialydesined dal apper (Section $3.1) 10 bande the rw prt ad insted parts during the nloadingoading retin of he work yl. Tn presses other than machining, various techniques ae used fr pars storage. In some ess th starting materiel isnot adsrete work prt sillstated by the following examples + Stet metal stomping. in sheet meta pressorking, automated operation of the pressis accomplished using a starting sheet metal col, whose length i enough for ‘ec. 142 / Single Staton Avtorated Cais m eae cutie Teggeee Figure 144. Alternative designs of partsstorage systems that might be wed with CNC ‘machining center: (a) automatic pllet changer wit pallet holders aranged radially, part storage capacity = 5 (b),ilne shuttle crt system with pale oles along is length, pats-storage capaciy = 16, (pallets held on indesng table, rar storage capacity = 6 and () partsstorage cause, partsstorage capacity» 12 hundreds or even thousands of stampings. Periodic attention i required bya worker to change the stating cul and remeve the completed stampings + Ploicinjection molding. The staring molding compound is inthe fo of smal pl lcs tat are load int shopper above the beating barrel of the molding machine. ‘The hopper contains enough mata for hundreds of moked pars. The molded parts restored temporary ina contzinerbenath the mold A worker pecioicalyatend ‘the machine by loading plastic ino the bopper and collecting the molded pats. In snglestaton automated cell for assembly, parts storage mast be provided for ‘each component aswell a the asembed product Various pat storage and delivery stems are discussed in Chaper 17 on automated assembly. 1423 CNC Machining Centers and Related Machine Tools Many sng tation automated cel aro signed around compatr-aunesil contre ‘mechne tok, This section dizustes four important atgois ofthese automated a chins (3 machining coer, (2) tanig center, (3) mit eater, end (4 muttasking machines, The objective behind al ofthese automated machines 0 rede te mut of separate axitarioes ad couespnding setups by which «workpieces procsed fo3m Hoe [a ta [ea] [Mesa] [Mow Tan 2 Wane» Figure 145 The ctectve of machining centers and related machine tool i oredr ‘he numberof separate mochines and setups eqsired to proces given part asin a) toss few as posible, ideal single machine and setup 25 in) 25 few as posible, ideally one machine and one setup (Sutegy 2 Combined operations Seaton {42), The objective f depicted in Figure 5. 18 addition to thee application in automated cel, these machines can eso be used ina semiautomated mode. Whether it operates with a worker in attendance of as an automaed single station depends om the existence ofthe enablers discussed in Section 142.1. The machine tools discussed here can aso be used in exible mantic. {ting cells are systems (Chapter 19} Machining Contes, This pe af mchine was bri dics in Stan 7A machining center, developed inthe at 9 9 machine tool capa of pcerning tulle moti operations on «work part none seo vee NC pos cote Todays machining conn are CNC with contol of four ove ae: Tp ating op rations perfor on a machining center rotting eon ole operation sh ssi, eigen, ad epi ‘Machining centers are ced a eric, Nrzna, or uavera. The desi tiomretersto he entation ofthe mache spindle A vera machining center as spinon aerial treat the workable, nd horizontal machnng enter pine ona hsizomtl rs. Th dineto general resin aiferenc nthe pe wrk tht is perfrmet on te moc. A vera machining cone (VC) peal {edo at wrk that reqs ol aces rom the top Examples ince mold and de Cavan ge component of ial A oriental aching center ADC) ise fereabe shaped parts where tol crs can bs be achieved onthe ses of thecbe. A tniversal machining conor (UMC) has a work head tht vive iting ait any angle betnenhonootal and verte, ming ih avery feible machin foo Ai "apes and oter cance geomsis often equi the apbites ofa UMC: ‘Names conto mchnng centers re iged wth feats to rede onpo: tac tine. Type etree + Auomatc ot chager. A vavcty of machining operations mesns that varity of cating tools is required. Te tools ae cntained in too storage uni hat is ine trated with he machine tool, When acute neos tobe changed, te too drums ¢- latest the proper poston, aed an automatic tol changer (ATC), operating under part program contol exchanges the toot the piel forthe tol inthe tol serge unt Capacities ofthe too storage unit commonly range from 1610 8D cutting tok gen 142 / Single Sutin Automated Cais s + Aon wok px poston May hrc nd uel ann snes fave cpshiy tone te nr prelate spe The aso ple by mean of try tte on ih the pst le The ae cn te Sceted aan sg ota erica ro pera ctg alo estat theenteifce eth patina ge stop + durante can Nang ets olen cqipedith wo orm) Sarat ple at con Depend othe cing el hg ona pet clanger (Seton 422), Whi ching is being pore ih one pal poston tthe mac ke oer pat sina sf extn ape ome ie, Tne lsat th oper cela ti fied po om he pele sadn xo tee wok pt forthe vert ‘A numerical controlled horizontal machining cate, with many ofthe fetes mis wed, then the chines will have ile time, snd the evel time of the machine cluster wll be the tine it takes forthe worker to Serve the my machines, which is (7, + J). The corresponding cos per pieces given by Gla) = (C+ Caray (+) 41410) “The elation of mor sbased on whichever cseresulsin the lover ect per werk uni Tm the absence of cost data nceded to make these eaeulatons, it is generally pet ‘erable co assign machines to a warker such thatthe worker has some idle ie and the tmachines ae ulized 10%, Tae teuso fortis is that the toal hourly cst rte of production machines is usually reter than the labor rate of one worker. Therefore mae Chine ile ime costs more than worker idl tine. The coresponding number of machines to assign the workers therefore piven by ett, TT, ‘ny = Maximom Integer = 414) EXAMPLE 144 How ofany Machines For One Workes? 'A machine shop has many CNC lathes that operate on a semiautomatic qe under ptt prosrane control. A significant nuber of these machines produce the same pat, ith a machine yee time = 2.75 min. One worker i required to perform unloading ad loading of parts athe end of each cycle, Thi takes See, Determine how many machines one worker can service fit takes an average of 2 see to wal: between the machines and no machin ile ime is allowed Solution: Given tht Ty = 2.18 min, F, = 28sec = 0.4167 mie, and TF, = Dsee ~ 0353 min Equation (14.1) canbe sed toobain 2) =m ech worker can be asigned four machines. With @ machine gjele Te = 4.1667 mi, the worker wil spend 4(0.4167) = 1.467 min servicing the me chine, 4(03333) = 1539 min waking between the machines, and the worker's ite dung the cyl willbe 0.167 min 1030). faview Questions 205 Note the regularity that exis inthe workers schedule in this example Imagine te four machines aid ou on he four corners ofa sauare,s tha the worker services each mauante and then pivceeds clockwise the machine in the neat comer, Eacitcyele of servicing and walking takes 30 min, witha lack time of 10sec left ove forthe worker. If this kind of regularity characterizes the operation of a costo of single station automated cells then the same kn of analsis canbe applied to determine the number of cells to asign to one woske. If, onthe other hand, servicing ofeach cells required at random ad unpredictable inter- vals, then there wil he periods when several cells requir servicing st the same time, overloading the capabilities of the human worker, while during ther periods the worker wil have no ells to service, Queueing analysis is appropriate this case of random service requiemens. REFERENCES {Anns Sigh Con” Mecha grey 26,9 22 BP} Atowov- Bisse! hin Too nucng Epc, ty 30, pos (5) Droz TJ, and WiC, Eto, Toon Mansi gers Hondo ed, Vole ating Sse ofMtactaog Ege Bet... (H) tomer, 1. “Motintng Macinne” Mncring xen, Rey 20 ® [5] Lone Jb Say YMC" Manfctin ngeig, 208 9. (6) Lames 1, "Mahins Ere fb Om Seip Heer” Montane Bxgeing Spee 2 p92 races I) Non, AT Monat and Yau “sry ad Caren Statin Mi Tking cies oral of SMEs oe) 208 (8) Wovens, Py “Prpanming for MTV” Manjari Expiring, Api 205, oo (9) eweisemsoa (0) whem {i} wewaatnocon (8) wane com review questions TL Name ee sons why singe stun manned cols are so widely used in indy. M2 What doe thet semiauonad aon mesa? 143 Whtisa single-sctn astomstod cl? [MWh ae the fie enbler that ar equ for ustended operation of automated els signed to prodece ident prior products?236 PROBLEMS 16 147 us us 10 ua (Chap 14 Single Station Manufacturing Cts ‘What are the dition ie nas ht are eguired for natended operation of snaed ces designed fo prot asi? ‘Whats an suo pol changer? What is smehining center? What te ditferance beeen» ortotlm hing comer an verte machining What ae some ofthe features of NC onchiring center used to vedeenonpodaine timeinthe work eh? What ithe diference between a ting center anda mlMurn eter? Whats aactine caster? ‘Answesto problems beled (A) ate stent append. Parts Storage and Multitasking Machines mat 3 (AYA CNCmackining ceter bas programmed cyl ine of 250 mi fo a ceri a. The ine to unload the nied prt and lod a starting work uit = 5.0 ie) Tend ing snd unloading are dove delet te chine toll and no aati soa ‘apc exss athe machine, wha ae the je tine ad aly product ate 8) ‘the maine ol hasan strat pall change so tha ulead sd lang canbe camglshed whi the acho isang seb prt, andthe regen tie = 3 ‘a re the total ee ean hoary prodoction ae? (If be acne oa as 38 uiraipalet ager tht interfaces wth apres storage uit hoc capaci 12 put, ‘aud the reposting nse = SO se, wt ae the fll le tie and uty prodcon rate? Also, how Long does tae to peer the loading and wrloading ofthe 12 patsy the uma worker, and what the tne the machine can operate wnatended bane purschangs? [A machine shop operates oe Sr si re day per week. Each reese on CNC ‘machine oo of interest as 2 proammed ec ine of 37min At the end of ac po rimmed jel a worker ease an ede the machine which kes Sn Thu thea ‘ork ce tie min, an the wake ile mo of hat ee. The plat ange seeds increase opt se iscomsiering tue aemates() stl an atomic pall ‘hanger (APC) tat wouk! have a repetning tine of 3D ee, atch wold inte os pat sighly, 2) purchase second che wth no APC, whch would doable out ot (©) purchase an astomated pallet sage and hase tem witha oragecpacy hi ‘fier to alow the macine toopecteoverigt (o sit), wich wo spr ely plete oxtpat. The epsitoning tine betwen the storage sytem and te CNC ‘machine 30s The worker would unload apdlond the sorage se athe bingo heey sh nd ten be aged cer wok ntl tern the shit whe wou be ine oa the serge sytem for overnight operation. Uniting and eclg ofthe ARC (andthe storage stem in (ae he same nin per eee case bt nve pak at Deters) he ongt per wek foreach of he hos alles (he tog capac ofthe sage stem In leretve (3) th would sete overig epraen, ‘(th sma of tine te worker would beep bay cach ay unlding sad thestonge sytem, ‘A bach of 35 pars i ordered by a astomer abou every sx moat. Te pat at rent procs sequently ough fie conventional skins, sted inthe falling 287 ‘able with ep tme nd wor etme per pee. These machines all ee a 0p: erator to be in atendce daring the wok je, There a Jy of 10 machine dae to tensor beten ass and wat jin queues of of pars prossed by these ‘machines. A recomend has boon mde a proses the prs on anew meiasking rmchine ta woul! eomplet the atch none wtp, whch woud iro simple ite ad sup tine of 20 he. The work cyde on the malisling cine con Of ‘ame operation tht are asamp by the fe machines, a the le ime Wald Be esta the som ofthe five cyl tines by one hal eae foo path provements and reduced prt handing. Determine the manuftig lea ine (Ho long ako «anil the bth of35 pas, incldig delays) fr processing onthe ive conventional ‘machines and () te maaig machine, Aste hata dey 6 10 wos cr for the raising machine det other wok x that machine Mastin SeupTine Work GyleTine Engin ashe enn ofzonta mill 25h amin Verical mill, 18h amin Dall poss 30 min Inn Dail press Sain Sin Determi 1g Workstation Requirements 44 (A) A ttl of 9010 stampings must be prodecd in tho pres deperinet rig te nest thre dys Maal epered press (on opetso per pe) willbe ie to complete the jb andthe pl tine 24 se, Each pros tbe set wth pnch-nd- Best bore production sts. Seu ines 2.0b, nd avalos assed 0b 100%, How tay press and operators must be deve to ths redvton dr he then das, theres 75 br of sale tin per machine per day? A stomping plant must ply on automotive fil ssemBly plant with bet metal tam ings The plant operates one Bx sto 20 day and met pode 5,00)000 pod ‘qty stampings nna, Btch size = 8000 good tapings pred per bach Sap rato = 3%. On aaa tales 40 se to proce each taming when the pene are ‘ain Before each ach th pes mit bese, an ht fer 25 he per setup Avoilby of the press i 95% dug preducon and 1008 ding setup.) How ‘any taping pases wil bs required to accomplish the species producto? (9) Wast the proportion of ine spent in stp fresh batch? U6 ner ogg plat mst pry pars oa eontrustion equipment manufac Forging isa hot epeation othe plat will operate 2 ay, Se day, SD wc. Tal ou ut ra the plant ms. be D.C) Kring per yearn tes of 125 pats pe ath Antsgnted rap rate = 3%. ach forging cel wil const of aaa that the pas, 8 forging pres and atin press Part are lacedin he fac sabre tof ey ae thes removed fred and tinued oma ine. The complejo kes 5m pet pat ack imea ew bat started, the foing cel mst be changed over, ich cons ‘of hanging te forging and tian dies forthe net party This takes 35 eon aver se. Fah i caused 1 be 95% real (svuiabiy = S6%) during operation sd 00% real daring changeoes a) Determine de numberof forging cl that would be reuedinthe new plant, (0) What sth roprtin of ine spent ia eup foreach bate? 147 (A) A plastitjeson malig plant wlbebutinprosac 000 600melded psy THe plan wlan tho sis per dy, fie dys, 2 wie. Poplin pupae, the erage batch 0 » 5,00 moldings, average changeover te between Bates = Sr,28 Ms wo rr) wa Cchep 14 Singl-Station Manutactring Cty and average melding ele tne pe ptt = 22sec Aste Scapa = 2% baa say for ech ming machine = 97%, which aps to bot run ine and chang fe (2) How may mln cis ace eguadia the new ple? (0) What be ing euied io produce ee ate ‘A ph exnason lant wil be ito prod 30 millon mets of pli eta pe ‘ea he lat wil ante Br sits per day, 60 dase. Fo planing aos, Enerage sun length = 70D meer of exuded pase. The verage angere tee be tween ets 25, atd average exrain speed» {Smimin, Assume sap ate = 1, tnd average opine proprdon per etsion machine = 95% ding ran Bean 1 ting changeover ath exton och eis oor a of by 25 nde ‘Sanalowene of 4% rides andi pce, whats ie na ates he exon pa? usure production requirements ina machine shop cl or sveral soma ar making tobe ede to prods tre nw par (A,B, nd C- Annis quae 04} Uines ecto ire part ae gen a the able bel: The machine shop operates ene Be hi foc 290 app Te ahies ate expected wo be 95% ell, andthe sera ale 638, for may automatic bar macs wil be oguie o met he pected annual demand forthe theses pai? Asuna step ies are negli Fon Bonwal Demand Mocticing ye Time R 75000 84min 8 aea00 Tomin c 1.000 10min A cote pe ort wi we grocer thre poa A.B nl CS foe ASSET ibe pen wes 420 and 000 sry, expec Pre Sst thee protest, 1215 95 Why aa eaprateee ag sse sans Te pa leer nk. Sha “Spa rosson michel se wl be down reps ara 1% Site ony maces il te ee tomes Seno? Ase Set es Somat fn eee sass en in iting artnet eas te hp ying ange eed pt fe sn ooo er ak on Fy ee 1 Sra Some fmt eprint ere De cea he pr ‘hosp droge wen wet A of Def ee asin pone She poscen ye ter art = fen Each ling hin ed teh Joma ot eae we le SOA A ap rt of cn be ged ASHE ni = 10%) ihe prodason vest ests 1 sis 9 80 ei, oe ‘any muti ie ear ao tappen ht nl omg shies {ped er cn to spy sine pare. To ie wih eeu aration pont manent ba anv! ees pein lacnontek Chie £00 epee parse cone iia ee os? ‘aca hp us ve CNC wer mating centr (VHC) prod 00 pts Gina ap ctl tecempays an poet The VC espe han kame {Sher cage (APO ands pts sae yen tht al 0 pat One ond ‘se pode raw and oso prt eine roe Par Ab ‘Suey gen 0 mi Put hv machin ol ine of me, Tes tc ie hep oth AP. Ro cageove ie tees pre Te tpn soy es, The moshing et 95% re. Te mai sop ents) cee Ho ny hon met he CNC ashing coer operat) {Sap sere redo? problems 08 (Machine Clusters AI3 (A) The CNC tg 2 Son as 2,» number of mad devoted to rndng buts for the evo indy. The pining eye tes 36min nd prods ne par. At tho end eat el, an opestor must bo present slat andlend pars, with ake, ‘ee (a) Determine bo many ii chines the woke can see iitakes 30sec towalt btwer the machines and no machin itn isllowed() How many seconds ung the work eye the worker ie? (6) What the Bout peodoeos rate of his machine hse? 1434 A yorker scorn response for ending wo aches in» machine str, The vr ‘ce tins por machine 035 min andthe Geo wa Between machines O15 min “Tae machine auton cyce tine 1.0 min If the worker's oust the Boulet foreach mashioe = SIN, determine (a the unt ory rae fr te ‘haters (t) th tet cos per nit of produc. ver that to ita prodced by ‘ach machine ding each machine cyl (} Whats the erent if tie of he worker? (@) Whats the optimum abe of mucins tht soa be used inthe machine csr, ‘ite co per ant of prod ise dein eeroa? MUS. Inamacine duster, th appropriate number of prodition mahi toss tothe wre ‘tobe determined Let = te muber of machines. ac pofucon ache seta andtsn sont prcesing tine T, = 40 min The ering ee T, = 12peforeach ‘machine The lee time for ech asin in th ce is 1, + fy The reposting “me forthe worker sien ty T= 5 +, hase Tin Sex Trees wth because The dst between mahi ices with more macs) Detemice he msi nerf machin th al ino machine alloved Fer your ase, compute (bj the epee and) the werkride ine aprened ss percent tee tie 1416 Anindustial robot ill ees mprodastionmshiesina mactne hater, Al production tchinsaeideteaandbave hesame procsng ine of 13sec Therobo servicing and Fepostoning tne foreach nahi zen by he equation (T, +7.) = 15+ 4, whee ‘Tastes tie Tsao reptioningtin (ce) andn = mamberof mache that tbe robot eres (7, +7) increase with recat more te needed to repos tin theobot ar inretes The fll jl efor each maine whee 1,= 1 * I (G} Determine th matimun number of machines inthe cel ac hat machines ar not eptmaking For your ane, () what the machine plein, and (what ithe robot ‘deine ened asa percent ofthe yl tine 7.2 447A factory produto department consists of large numberof wrk cll Eat ell come site of one hema woke erring electronic esebl tasks The ols ze ogni inf secns wii the sparen, end one orem sper each scents tofnow hw many work cl shoul be assigned to cach rer The formas co- sts of wo tars) provide each el with ascent spy of parts tan work for ‘Ab before it need to be espe snd (2) prepare proacon repo fr cach work cel Ts (1) takes 8.0 ion average pr wetkeland must be doe tice per dy. The foxeman mst sede the resppyf rt oor ells that no ifletine occurs in any cel Task) akes 90 min per work and musts dose ene pe dy. Nei the wo tevnorthe oer arsed to wenkmar th 80 ly. ac oy, th cal cominas rodusion fom where they oped the day before. (2) Wists te rtxinum somber Work cle tit soul be ssged to foreman, on th cnt hat he wok els must ver be le? () With the be of work els om put) how many i minutes oes the foreman ae exch 6?Chapter 15 Manual Assembly Lines ‘CHAPTER CONTENTS 181 Fundamentals of Manual Assembly Lines 15AL1 Assembly Workstations 58.12 Work Transport Systeme 1513 LinePacing 15.14 Coping with Produc Variety 152. Analysis of Single-Modal Assembly Linge 182.1 Cyclo Time ane Weorload Analysis 1522 Repositioning Losses 1623 The Line Balancing Problam 183 Line Belancing Algorithms 18231 Largest Candids Rule 1832 Kilbidge ond Wester Method 18.43 RankogPostonal Weights Method 154 Workstation Deas 185 Other Considerations in Aesembiy Line Design 188 Altemative Assomby Systems Appendix 1A: Betch- Model and Mixed Mode Lines ‘6A Bateh-Model Assembly Lines 16A2 Mixed Mode Assombiy Linas ‘Most manufactured consumer products are asembled Each product consists of multiple. component joined together by various assembly proceses. These kinds of products ae hap. 18 / Manua! Assembly Lines in ‘sally made on 2 manval assembly Hine, Factors favoring the use of manual assembly lines ince the fllong: + Demand fo the produc ishgh or mein +The products mado onthe lin re dential or sinter + The total work required to assemble the product canbe divided into small work elements + Tstechnologiely impose or economical ifesbe to automatc the asely operations, A fist of products characterized by these factors that ate wsully made on «manual as+ ‘sembly ine are presented in Tble 15. ‘There ae several resons why mauval sembly Eines are vo productive compared to alternative methods in which muliple workers each perform all af the tasks 0 a semble the product. + Specialization of labor. Caled “fvision of labor® by Adam Smith (Historical Note 151) this pricile asserts that when a large obs vided inc small tasks and each tacks asdgned to one worker, the worker becomes highly profient mt performing the single task. Each worker becomes peda. Interchangeable pars, ia which each component is manufactured to sulicenty ‘ose tolerances hat any part of eran type canbe selected for assey with its ‘ating component, Without interchangeable parts, assembly woul require fing and fing of mating components, rendering assembly line methods impractical. ‘Wark flow principle, which volves moving the work tothe worker ater thn vce versa Each werk uit fons smoothly through the production line, traveling the rminimum distance between stations Line pacing, Woskers on an asimbly Tine are usually required to complete their assigned tasks on each work unit within cotan yee time, which paces the ine to ‘ainsi a specified production rate. Pacing is generally implemened by means of mechanized conieyer, Inthe present chapter, the enyinering and technology of manual acembly ins are discussed, Automated assembly systems are covered in Chapter 17 TABLES. Products Usa Made on Manual Assemby Lines ‘Audio equipment Elesiemators Pans ‘Automobiles Furniture Refrigerators ‘cameras Lamps Stoves Celi phones and emer Luggage Tablet computes phones Coating ranges Mironave ovens Telephones Dishwashers Porconl computers and —_“Tosstrearetoastor ovens Dryers Vaundry ‘ecgherals keyboards, Truds, ight and hoawy ND players pinto, merits et:} Video game console E-Book eaders Power oo ris, saws etc) Washing machines aundry)se Chap 5 / Manual Assembly Lines Components skcett nt ion A ee ral fas] fos] Ps 727] cmt ey, _. fet] fel fe], fe] : fel es so0edo oS ew 000000 = © 2 oF SS eae Figue 15.1 Confgoration ofa manual aserbly line. Key: Asby = assembly, Man = ‘manval, Sta = workstation,» = numberof ations onthe Hine 15,1 FUNDAMENTALS OF MANUAL ASSEMBLY LINES ‘A monealessembly line isa production line that costs ofa sequence of workst- ‘ions where assembly tasks ae performed by human workers, s depicted in gure 15. roduts re asembled as they move along he lin. At each station, a worker performs a portion of the total work om the nit. The common practices to “iach base parts onto th beginning ofthe line at regular inervals. Each base par travels through saccesve slations and workets add components at progressively build the product A mechanized ‘material transport system is typialy used ko move the base parts along the linea they ae gradually trastormed into fil pric. The production cate of an assembly lines determined by its slowest station, Stations capable of working ester are ultimately i ited by the lowes sation. “Manual sembly line technology has made a significant cntibuion to the devel opment of American indus in tho 20th century, a indicated in Mistoricel Not 151 Weems aa important production sytem throughout the woe inthe manner of automobiles, consumer epliances, and other assembled products listed in Table 15. ‘Mandal sista jines ce hese lng oo fondamatal ork principles. Te Hs lv of aor, propo by Ada Sah (1723-1790) ini book The Wea of Nao, “ahi pas jab Elna 76 Usa pin aon wots te dren of ibs, tbe dsces bow 1 wines kpc i the vero dit sts ried) mae fin 10ers por ay Tas was oad ever tic cach iter perro fie ss en cath is al peed only xT Ph ‘ed Shih i cent cn oho, tee Pd ven example of -Eviegtor cen bute ws th rt 6 ts siibanes in pode: tye scond work pre inital prs, based oth ers of BA | “whiny (765-1625) and oes ae Bentnng ofthe Ik entry 15}, Te cc oft + Inlcchageabl prs pace were peo descibed in Historia Note 1.1. Without ‘icehagate pats ase ie ecosicgy weld ot be posible ‘Ths vig oera podem ns canbe acd othe meat industry in Chieg, ‘is sad Cacnat-Obe ie wid 388 Ine EN, packing plan's wed ue | poesed overhead conveyer to move fe shed sc fro one waft et "es perl cao wee ter sepled by poner-ven shai havo 6 create ‘90.161 / Fundamentals of Manual Assembly Lines oy “ce neha vt i pedis eee sig sone nora Hea Fg © apt Ms engineering cleats coamapeotnien ha ia Eadie bak ms ae Heats iconest aa | 15.1.1 Ascombly Workstat A workstation on a manual assembly Tne i designated location along the work flow path at which one or more work elements are performed by one or more workers. The ‘work elements represent small portions ofthe total work tha mst be accomplished to assemble the prodvt. Typical assembly operation performed at tations on manual assembly line are listed in Table 152. A given workstation also includes the tools (hand {oaks or powered tos) required to perform the task ssigned othe station, ‘Some workstations ce designed for workers to stand, wile others allow the woth ers to sit. Whea the workers stand, they can move about the station ares to perform ‘heir asgued task. This is common fo assembly of large products such a ats, tuck, and major applances. The products typically moved by a conveyor at constant velocity ‘rough the sation. The worker begins the assembly task near the upstream side ofthe station and moves along withthe work unit until the tsk s completed, then walks back to the next work unit and repeats th cycle, For smaller assembled products (such as small spplancs, letronie devices, and subassemblies used on larger products), the worksta- tions are usualy desiged to allow the workers to sit while they peform their sks. This {more comfortable andes fatiguing for the workers ands genealy more conducivo to precision and acearacy inthe assembly task. Additional details related ro assembly ie ‘workstations are dscasse ia Secon 154. ‘TABLE 152. Typical Assonbly Operations Perfomed on Manus Assembly Line Zepto of adhesive Expansion fitingapplistions Snap fing oftwo pars ‘Applicaton ofgasirt—Ineerion of components Soldering are weleing Press iting Spot welding Brezng Printed crcutbhoard assembly Steping Coser pin apoications Riveting and eyelet appications Siching Cimping Shrinking sppicaions ——Threodod fastener eppiationsi (hap. 18 / Manus! Aesembly Lines 15.12 Work Transpoit Systems ‘There are two basie ways to accomplish the movement of work uss slong a manuals. sembly Line: (1) manually or (2)by areechanized system. Both methods provide the fies routing (all work units proceed through the same Sequence of station) thats characte. isco produstin fines. Manual Methods of Work Transport. In manual work tansport, the units of product are pased from sation to station by the workers themselves. Two problems rs sult from tis mod of operation: tacving and Hocking, Starring isthe situation in which, the asembly operator as completed the assigned task on the cutent work unit, Bathe next uit has. no yet arrived a the lation. The workers thus starved or work. Blocking ‘means thatthe operator has completed the assigned task on the curreat work unt but ‘anno! pas the anit othe downstream tation because that worker is nat ye eto reorive it.The operator is thecefve blocked frm working. ‘Tomitigae the effects ofthese problems storage bulfers are sometines wed between stations Tn some cases, the work units made at each satin ae collet in batches and then moved tothe next station. In othe eases, work units ate moved indvieally slong fat table or nongowered conveyor. Wien the tsk is fined al each station, the worker simply pushes the unit toad the downstream station. Space is often allowed for one ot ‘ote work unt front of eck workstation. This provides an available supply of wor or tho station, swell a oom for completed unis from th upstream station. Hence starving snd Docking are minimized. The trouble wit his method of operation isthat tan rest in snificant workn-proces, whichis economically undesirable. Ako, workers are un- paced nines tat rely on manual anspor method, and production rte tend tobe lover Mechanized Work Transport. Powered convyors and eter types of mecha sized materi handing equipnent re wtely wed to move wis along manual somby lies. Thes ystems canbe designed to povie paced or unpaced operation ofthe line Thre major categacies of wrk ranport tems in production fines ar (a oxic transport, (2) syntronoas transport, and () asynchronous transport. These ae i trated schemata in Figure 152. Table 15. ets cme of he ately. cqupment commonly sociated wih eich ofthese cateperis. ‘conimoasianport system uses continues moving conejo that opts at consant veloc, tin Figure 1523). This meted is common on mbul assay lines. The conveyor weal rans the eat ng ofthe ine. However, the ne i vey tong, such asthe ease ofa automo ial assembly plant, it died ita sere witha separate eameyor for each pment Contnsoes transport can be implemented in two ways (1) work unis re ed the coneyr, nd 2) work unis ze removable om the comeyon. ln the fist ase te prodvat sage and heavy (cg. automobile asking machine) and cannot be removed ftom te conveyor. The werkcr mus therefore walk long with the product tthe spend of th conveyor in ode to aezomplish he assigned tsk. nthe case where work uni ae smal ad lightveght, they canbe removed fo ‘he conveyor for the physical eantenienee of the operator a each sation. Ava convenience forthe workers that theesignedaskat he station ceesaoed to bo com ted within a fixedee tine ach worker ha xb t dea wih ecislproblens that maybe encountered wi a parila wank uit. However on average, each were smut maintain a prodution rat equ that ofthe resto he ne. Other, the Roe rodues complete us, which scr when pars tht were suppoad to beaded at Station ae not aed becaose he worker ra ota tine ‘gee 151 | Fundamentals of Manual Assembly Lines 395 Se sa Hi a Figure 182 Velociy-sance gran ard pyscal yout fortes tpes of mek ane transport ses wed in rodents: (a onto tanport, (2) 9 hronous spor an (6) asconos isp. Key. v= yl, ~ Stan relocy of contucustranspoet eoaveyer, x= distance in cenveor decton, Sia = nesktation = nrksatin ete, ‘TABLE 152. Matera Hating Equipmont Used to Obtain he Tivos Types of Fixed Routing Wer Transpor Depicted in Figure 16.2 Work TranspontSystem Material Handing Equipment (Text eteence) Continuous anspor Overwad woley conveyor (Seton 1024) ‘Belt conveyor (Section 102.4 Rolle conveyor (Secon 102.8) rag chain convaor (Seton 102.4) Synchronous tansport Walking beam tranepert equipment (Seton 161.3) Rotary indexing machariome Section 18.1) ‘Asynchronous wansport Powerendtoseverhesd conveyor Section 10.24) Carconirak conveyor (Section 10.2.4) Powered roller conveyors (Section 102.4) ‘Automated guided vehicle system (Section 02.2) Mono systems Section 10.23) Chainarven or bet riven systems (Seton 18:1) {In synchronous transport systems, all work wits are moved simultaneously be- ‘ween tations witha quick, discontinuous motion, and then psitoned at their espective stations. Depicted in Figue 15.2(b), ths typeof syste alo known eintermitent ans. Port, which describes the motion experienced by the work unit. Synchronous transport(Chap. 18 / Manuel Assembly neg {smot common fr manaal ines, due tothe requirement that the task must be complteg within a certain tne lini. This can cause undue stress om the assembly workers an result in incomplete products. Despite its dsadvantages for manual assembly hts, sy chronous transports often ideal for automated production fine, in which techarizng ‘workstations operate on sonstant eye time Than asynchronous tronsporsysem, 2 work unit leaves a given station when the assigned tsk has been completed andthe worke ekases the unit. Work uit move. dependently, rather than synebronously. At any moment, some units are moving between ‘workstations while ethers are postionod at stations, as in Figure 15.2(¢). With synchro. nous transport sjtems, small queues of work units ae permitted to form in font ofeach station. Ths system tends tobe forgiving of vaviatons in worker task tines. 15.13 Line Paving A manual assembly line oprates ata certain eye time that i established 10 sehie the required production rate of the ine. The caleulation ofthis eee times expaied ie Socton 152, On average each worker must complete the assigned task at hiser sation within te eee time, oF else he required production rate will not be achieved. This pc ing ofthe workers sone ofthe reasons why & manual assembly ine i successful. Poin provides a discipline forthe assembly Hine workers that more o ess guarantees aceta, Production rats. Prom the viewpoint of management, this is desirable ‘Manual assembly ines can be designed with three alternative levels of pacing (L) rigid pacing, 2) pacing wth margin, and (3) no pacing In rigid pacing, each worker ie allowed only a certain xed tine each oyce to complete the assigned task. The allowed time i inplemented by a synehzonous work transport system and is aswally) equal to the eee te ofthe ine. Rigid pacing has two undesirable aspects, as mentioned erie. Fis, rigid pacing is emotionally end physically stesful to human workers. Altbough soa Tetel of sues is condcvet npoved bomen performance fa pacing ona sembly line throughout am Shr shift (or Jonge) can ave hanmful eects on workers ‘Second, in a igily paced operation ifthe task has rot been completed within the fied le ime, te work anit exis the station incomplete. This may inhibit camplesion of sb Sequent asks at downstream stations, Whatover isk are lft none on te work unit the regular workstations mast later be completed by some other worker in order to yield an acceptable product Tn pacing with margin, the worker is allowed to complete the task atthe station itin a specie time range. The maximum te of the ange is nger than the ee time, so thata worker is permite to take mare ine if probler occu or ifthe ak ibe required fora pcticular work units longer than the average (this curs whea different prod styles are produced on the same assembly lin). There ae sexeral ways in whieh pacing with margin canbe achieved (1) allowing queues of work unis to frm between saions (2) desining the Ene so thatthe time a work unt spends ise each station it longer thr the cjle ine, and (3) allowing the worker to move beyond the boundaries of hich own station, In method (1), implemented using an asynchronous transport sistem, work units are allowed to form qusues infront of each station, thus guaranteeing that de workers ate neve starved for work, bu 9 providing exis time for some work unis a Jong 2 other unis take les tine Method (2) applies ones n which work unis are ined toa contimowsly moving conveyor and cannot be removed. Becanse the conveyor speed {sconsant, when the station length is longer than the distance needed bythe worker © 1.151 / Fundamentals of MaruslAesbmbly Linge a complete the assigned ‘ask the time spent by the work niinsde the tation boundaries (called he tolerance tine islonger than the cele tine. in method (3), the worker issimply Allowed to either move upsteam beyond the immediate sation f gt an eal srt on the nett work unit or move downsream past the eurreat station boundary t nih the task on the erent werk unit In ithe ese, there aze usualy practical ints om bow far the worker can move ustream or dowasteam, making this ease of pacing with mari ‘The tems upsream allowance and downstream allowance ace sometiaes set designate these ints in movement. Inal ofthese methods as long the worker maintains an ver: ‘age pace that matches the ele tme, the required ele ate ofthe lini achieved, The third level of pangs when there is ne pacing, meaning that no time lint ex- ist within whic the tsk attestation must be finshed. Inefex, each assembly operon Works at ister omn pare. This ase can oocur when (1) manual wrk transports used on then, (2) work uitscan be removed from the conveyer, allowing the worker oake as noch tine a desired to complete a given unit, or (3) a asynchronows eoaveyor is wed and the worker contol the release ofeach work uni from te station. In each ofthese cases there i no mechanical means of chieving a pecngdipin onthe fine. To reach ‘he required production rate, the workers are motivated fo achieve a cerisin pace ether by their onn collective wonk etic or by an incentive system sponsored by the coma. 15.14. Coping with Product Variety Owing tothe verailityof human workers, manalasembly lines canbe designed to dea with ferns in ssembled products In general, the product variety mast be estes st (Section 23). Three types of assembly Ine can be distinguished: (2) singe model, (2) bach model and (3) mixed madeL. ‘A single-mode! line produces only one product in large quanites, Every work unit is dental, so the task performed at each station isthe same forall produets. This line ‘ype isintended for products wth high demand, Batcenodel and mised model ines are designed to produce two or mere produts cor models, bat different approaches are wed to cope with the model variations. A batch- ‘model line produces each product in batches. Workstations are setup to prodace the required qustty of he fst product, then the stations are recotigured to produce the ‘next product, nd soon Products te often ascemblein batches when demand for esc prod is medium, Its generally more econonical to use one assembly line to produce ‘several prodacs in batches than wo build asepaat ine fr each citteren model. ‘Seting up the workstaxons refers to the assignment of tasks to ech tation on the line, including any special tools needed wo perfor the tsk, andthe physical layout of the station. Th products made onthe Line are usually sir, and the tasks to make them ace therefore similar. However, difeences cist among models so that a diferent, Sequence of aks vualy required, nd the tools wed ata given workstation or the last, ‘mode might not be the same as those required for th next model, One model may take ‘more total time than another, equring the Ine o be operated at aslower pace. Worker retraining or new equipment nay be needed to produce each new model. For these kinds of reasons, changes inthe station setup must be made before production ofthe next smodel can begin. These changeovers result in lost prodaction time ona batch mode! ine, 'A mized-model line also produces moce than one model; however, the model are ‘not produced in batches instead, they are made simulaneously onthe same ine, While ‘one station's working on one model, the next tation processing afferent model. Each(Chap. 18 / Manual Assert Ling ala [bom [Say [etm | Novara | Sigel Frac vay [Type neat Fe Figure 153. Three types of manual asembly line related to produt varity, stations equipped to perform the vate of aks needed to produce any mde that moves through i, Final assembly of many consomer products ae accomplished on mixed-mode lies, Examples are automobiles and major appliances, which ae chatacteried by mode ‘variations, ferences in availabe options and exen brand name diferences i some case, Advantages of mixed-mode ine over a batch-mdel line include (1) no lost pro- maximum service time must be no greater than the difference ‘between te epee ime 7 and the repositioning ime that i Nax(Ts) = h~T fori= 1.2, (58) where Max{ TZ} = maximum service tine among al stations, miley; T= ese time forthe assembly ine fom Equation (152), mineele; and J, = repesiioning time (as sumed the same for al stations), mice. For sinpiity of notation let 7; devote this maximum allowable serie time: 7 Max(T,} T= T (59) Atal stations where Ty less than 7, workers wil be ile fora portion ofthe eye, 93 portajed in Figure 154, the maximum service ine doss not eonsume the entire avail able ine (e, whan, < T;~ 7) it means thatthe Une could be operated axa faster pace than fo Equation (152), Tn hives, the cyte ie 7s usualy ede so that T.= T,4+ Fthis allows production rate tobe increase sigh, Repastionng kasses reduce the amount of time that can be devoted to productive asserbl work onthe fag, These losses can be enpressed in terms of an efieny factor as (519) oy where E, = reposionng eticency and the oter terms are definedeatlis, 1523. Theline Balancing Problem & ‘The work conten perfored on an assembly line consists of many separate end distinct ‘work elerens Invargbly, the sequence in whch these elements ean be performed is restitd, at lost to some extent, and the ine must operate ata speed production sy Pott i He time i | If | re I 1, Sessa Sa SS 77 FP SAF Figure 154 Components of cycle time at several stations ona manual assembly line. At the slowest station, te bottleneck station ile ime = zero, at othe sta tion ile tine exits. Key: Sta. = workstation, x = numberof worsttions on the ie, 7, = repositioning time, T= sevice time, T= eye time‘Chap. 15 / Manuel Assembly Lines "ate, which ».duees vo a required cjele time as defined by Equation (152). Given these coadition, the in balancing problem is concerned with assigning the inivtual work elements to workstations 9 hat ll workers have an equal amount of work. The tera nology of th line balancing problem i dscusodin his section, and several algorithms ty solve tare presented in Section 153. ‘Two importnt concepts fine balancing are the separation ofthe total work com. ‘ent into minimum rational work elements and the precedence constrains that must be satisfied by these cements, Based on these conseps, performance messutes can be do- fined for solations othe Line balancing problem, [Minimum Rational Work Elements, A miimum rational work element is smal amount of work tat hes a speci itd objective, such as adding a component tothe base pat, joining two components, or performing some other small portion f the tol ‘wor content, A minimum ational woek element cannot be subdivided any further without los of practicality. For example, dling Uroug-hle in pice of sheet meta or fasten Jing oe machined components together wit bol or srew would be defined as minimum ‘allonal work elements, Ic makes no sense to divide these uss into smaller elements cf ‘work, The sum ofthe werk element ness egal othe work content tne; that is, (sn) where Tg = time to perform work clemest i, min and n, = numberof work elements ‘nto which the work ontentisdvided, thats = 1,2... ‘inline balancing, Tx Values are assumed io be (1) constant and (2) adie. Infact, these assumptions ate not gute tue, Work element times are varebl, leading to te problem of tak time varabity. And ter is atten motion economy that an be achieved by combining two or more work elements, so the ine ro perform two or more work ee- _meisin sequence may be ess than the sum ofthe invideal element times. Nevertheless, ‘hese assumptions are made o falta solution ofthe Kine balancing problem. ‘The sk ine at station or servic tie asit scaled, Ts composed ofthe work clement times that have been assigned to that tation, thai, t= Btu assy An underying sumption is that all are less than the maximum sevice time T, Different work elements require diferent times, ad when the elements are grouped into logical tasks and asigned to workers, the station service times Tare likely not to be equal. Thus, simply because of the variation among work element mes, some workers wil be assigned more work, while others wil be assigned ls. “Although service times vary from station to station, they must add up tothe work content time: dn sa Precedence Constraints, In ation tothe vatation in element times that make itdfcalt to obtain eaal service mes forall stations, there are estrctons on the onder inwhich the work elements canbe performed. Some elementsmustbe done before others. See. 182 / Analysis of Single Medel Assombiy Lines 40 Figure 185. Precodence dngram for Example 15.1. Nodes rep resent wotk elements, and arrows indicate the sequence in which the elements must be don. Element times are shown above each ode, Foreaape octal trond hl te emt eed bef itcan be ape ‘Ammacie sen hat wl the aged ho sacha nating compen can be tse eo he he as ee le ne oped. Tese tele eu cn he wrk eqs aca peceene cnt. They compte ae eed te presented recone ons xn be peated graphical in he form of «pee ence dagran, ichs nto agra tha ets i ean sich the work clams mast be permed. Work elements ae symlad oy nodes ned the precedence requranent eine by sows oon he ode The ques pees fom et tight igi 19 presen he reteeace aa fo The falowing exam, mich fates te teinloy end some of eeu prevented ere [EXAMPLE 151A Problem for Line Balancing Asmullelectical aplianc>is tobe produced ona siale-modclasembl tine ‘The work content of assembling the product hasbeen reduced tothe workel- ment listed in Table 154, The able alo iss the times for ech element ad the precedence order in whieh they must be performed. The init be bl ‘nord for anannual demand of 10,00 nite. Thelin willoperateSD wis, 5 shits, and 75 hsb. There wil be one worker per station. Previous experience suggests tha the uptime eficeney forte ine wil be 95%, and ‘repositioning time lost pr eye wll be 0.08mi, Determine (a total work content me Tye (b) equired hourly production rate R, to achieve the an- ‘val demand, (9) cycle time 7, (@) theoretical misimuty numberof work x required on the fine, and (e service time T; to which the line mast be balanced,(hap, 18 / Manuel Assent Linge TABLE 164. Work Elements for Example 15.1 cs ‘Work Element Mut" = racssed ay Paco Fameinworthebdr andeamp 02 ‘Assemble pg, grommet to power cord 04 ‘Assemble Bracks to frame 07 Wire power cord to motor on Wire power cord to sateh 03 Assemble medtanism pletoo bracket =O. ‘semble bade to basket 03 “Assemble motor to breckes os ‘Align blede ad atch to motor 02 Assemble suite to moter bracket, 02 ‘toch cover inspect and tact. 0s ote pan for pecking on Pl Sotution: (o) Toe total woek content ines the sum ofthe work element times in able 184, Tre* 400 {) Given the annual demand the hourly production rae is on 4 3\c5) (0 The corresponding cyte ime 7 with an uptime eciency of 96% is 01096 Cs (@) Te theoretical minima number of workers given by Equation (157) 108 nia 40 v= Minin = (€)The available service tne against which the ine must be balanced is L 37 rounded up 04 workers 98 — 008 = 1.00:nin Measures of Line Balence Efcioney. Owing to the diferences in minimum rational work element times and the precedence consrins among the elements, itis vir twaly impose to obtain a perfect line balance. Measures must bo defined to indicate how good a given line balancing solution i. One posible measur is balance efficiency, ‘which the wok content ime divided by the otal avaiable service ime onthe line: 519) where Ey = balance efficiency, often expressed as percent; T,= the maximum avai abl service time om the fine (Max{75}),miveyele; and w = number of workers, The <éenominstorn Equation (15.18 gives the total servic time avaiable onthe line to de> vote to the assembly of one prosict unit. The cose the values of T,< and wf, te les 02 153 ! Lin Bancng Algorihins 05 illic on ic ies terefoe a measur of how god th ne sain sition A pete ite blancs yl valu of E, = 1.00 Typical ine blencng elie in ‘nds cane between 09 and 06, The complement of blanc eins is balance delay. wich nae the anus. cf ime ls dv to pest alneing aaa othe otal ims aaa, hati (wh - ho : = asa) where d = balance delay and the other tems have the same meating as before, A bale noe dele of ero indiatsa perfect balance. Note that B, + d= 1 Worker Requirements, In discusing the reationshps in this section, three cftceny factors have been identified that reduce the productity ofa manual assert ne: 1. Line effcine, the proportion of uptime on the line B a defined in Equation (sa) 2. Repositioning efcioney, fy as defined in Bgnation (15.10) 2. Lin balancing efficiency, Es, defined in Equation (15.14) ‘Together, they consttte the overall labor efficiency onthe assembly ie EB (519) Using this measure of labor effcione, a more realistic value forthe numberof workers ‘on the assembly line can he calculated, bated on previous Equation (15.7): Re | Te. Te BREE,” EET.” Esl, where » = actual number of workers required on the line; R= hourly production rate, unis; and Tye = work content time per product to be accomplished onthe line, ‘mint. The trouble with this relationship is that iti dificult to determine values for E,E,,and B before the ini built and operated. Nevertheless, the equation provides an accurate model of the parameters that affect the numberof Workers required to ac- complsha given workload on single-mode assembly ine Assembly line abo efficiency vw = Minimum Integer = (asa) 152. LINE BALANCING ALGORITHMS ‘The objective in ine balancing sto dstrbute the total workload on the assembly ine 36 ovonly as posible among the workers. This objective cn be expressed mathemataly in two altemative but equivalent forms: sins ote) ine $57) asin or a ae fee 08 (2) all precedence requirements are obeyed.(Chap. 18 Manual Assembly Lines ‘TABLE 165. ork laments Arranged AEDordng to To ‘Yue or he Largest Candice ule Work ene Teli) Preceded By 3 oF 7 8 08 a4 " 05 a0 2 04 - 0 038 58 7 ox 3 5 0s 2 8 oz a18 1 oz : 2 one a 6 ont 3 4 a 42 “Thisszton ovr sve agrithns tose the ne lading role ing he date ofFaamzle 1 oilstt, They ae) gest cnt ale, 2) Kiba nd Wester method nd) cal potiona eis method These eth ae hes, sneaning they are buedon common ese ndespernentaion ater tan ate {pmationIneacho te alts, there ron worker erste, 0 when ering toa cern sation thet reference cies he worker a sation 1531. Largest Candidate Rule Inthis method wok elements are arranged in descending order according fo thei values, as in Table 155 Given ths st the algorithm cont ofthe foloning steps (1) assign ee- ‘mento the worker athe fst wotksttion by tating a the op ofthe stand seeting the fistelement that satisfies precedence requcements and does not cause the total sum of Ts that station to enced the allowable 7; when an elements selected for esignment othe ton, start back tthe top ofthe istfor subsequent asionments (2) when no more element ‘canbe asigned without exceeding [then proceed tothe next station (3) repeat eps and 2foras mary adctonl stations as necessary unt llelementshave been assigned. ~ EXAMPLE IS2 Largest Candidate Rule Apply the acest candidate rule to Example 151. Solution: Work clements ae arranged in descending order in Table 155, and the algorithm i carted ut as presented in Tale 186. Five workers and stations are roquiced inthe solotion, Balance efficiency is computed 40. 5p = 20, The ae balancing solutions presetedin Figure 156. 5 Balance delay d 51.153 Line Balancing Algorithme ro ‘TABLE 156 Wore Element Assignesto Station According to he Largoet Condes Rule sen Tei T 2 04 5 03 1 02 4 a4 16 2 a a . on ast 3 & ae © ri oss 4 7 a3 3 07 as 5 * 05 @ on 062 _ sain a oo sunt | SOC o $ Suns eae 8 a @ 0s 5 O) Sion Sana? Suen} Sond ——_ Sons Wot_[ Bene | Eemee | [Binet LL ema | aaoee oe] ae fo] Se Pf Sa P| ite 7 ® Figure 356 Solution for Example 152, whic indicates: (a) assignment of clement anording to the largest candidate ul, and (b) physical sequence of stations with signed work elements. 153.2. Kilbridge and Wester Method ‘This method has rceived considerable attention since it introdvtion in 1961 [18] and hasbeen applied with apparent sucess to several large line balancing problems in industry [2] Iti bourse procedaro that selects work elements for asignment(Chap. 15 / Manual Assembhy Lines ta stations according to their poston in the precedence diagram. This overcomes oe ofthe dlicales with the largest candidate rule in which an element may be select ‘because of high 7 value but respective ois y.siton inthe p, sedence diagram, if genera, the Kilbrdge and Wester method provides a superior line balance solution ty that provided by the largest candidate rule (although not for this example problem), In the Kilbridge and Wester method, work elements inthe precedeace diagram are arranged into columns, as shown in Figure 15,7. The elements can then be erga ied int a list secording to thee columns, wit the elements nthe first column lie fis. Such a sto elements has been developed forthe example problem in Table 157 connaa i au Ol into columns forthe Klridge and Wester method. TABLE 157 Wosk Elements Listed According to Columns fom Figure 15:7 forthe ‘ieiige and Wester Method Vio Element Column Toa) Preceded By ~ 2 7 04 Z 1 “02 - 3 1 07 1 5 a 03 2 4 © a1 42 8 mw 06 34 7 mW 032 3 6 " oat 3 0 038 58 9 w oz 578 0 v 05 310 2 012 1 en 154 J Line Beancing Aigorters my Ia gies lementcan be ested in more han one clu, ten al fhe clus for that elemeat shoud belted s inthe ease of element 5. An 2ddtonal etre ofthe lists thatelemensin a given coluan are presented in the order of thei val; hat, isthe langst andiate ule hasbeen applied in each column. This hep wena sigingelemeat to statins, becuse tenures thatthe larger element are selested fr thus increasing the chances of making the sm of Tin each tation lst the allowable Tint. Onc the tients, the same three step procedures eed as before. EXAMPLE 153 Kibrdge and Wester Method Apply the Kilbrdge and Wester method to Example 15. Solaron: Work elements ae arranged in order of colunns in Table 157. The Kilbride ‘and Wester solution is presented in Table 158. Five workers are required and the balance efceny is Ej = 080. Not that although the balance efficiency isthe sume asin the lrgest candidat ral, he allocation of woe elements t> stations diferent. ‘TABLE 168 WorkEloments Assigned to Stations According tthe ‘bridge and Wester Method Staion WorkEloment Colum oe 1533 Ranked Positional Weights Method ‘The ranked postional weighs method was introduced by Helgeson and Binnie (13). this method, a ranked poston weight value (call it RPW for shor) is computed for each clement. The RPI tokes into account both the Ty value and i poston in the precedence diagram, Specifically, RPW is caeulted by summing and all other ties for elements that fllow Tin the arom chin ofthe precedence diagram. Elmeats ae compiled into ist according to their RPW valu, and the algorithm proceeds wing the same three steps as before.Chap. 15 7 Manual Asser Lines ‘00154 J Workstation Detail 7 the line a his faster rate, wih the ces chat ine bance eticieney i im EXAMPLE 154. Ranked Posional Weighs Method proved and production ates increased: Apply the ranked pestonsl weights method to Example 151. not Solution: ‘The RPW must be calculated foreach element, To ilustate, 592) RPM, = OS + 0:2 = 062 DW, = 05 + 027 + 038-405 #012 = 187 ‘Work elements ate listed aoording 19 RPW value in Table 159. Assignment of elements to stations proceeds wit the solution presented in Table 1510. ‘Note thatthe largest 7; value is 092 min. This canbe exploited by operating ‘And given tht ine elieney £ = 096, R, = 6(0.96) = S76 uit T,= 092 + O08 = 100; therefore, o Rea The Moyer TABLE 158 Elomonts Ranked According toThlr Ranked Poston, Weights (APH ‘This ise beter scution thn the ones provided bythe previous ln balancing meth+ Fuareeneatl Sarena Rear ‘ds. tars out tat he performance of give ine balanengalgoridhn depends on the ment PW Toul) Proc eee problem to be soled. Some live balacing metbods work betes oa sore problems, while 380 02 : ‘other methods work better on other problems 300 07 287 oa 7 “7 iI 12 154 WORKSTATION DETAILS 1 068 ae 130 a3 2 inition, a workstation isa postion along the assembly line where one or m 1 eS : By definition, a workstation i a position along the assembly ine whe ore workers perform atsmbly tasks. This scton covers several additonal detals relating on 3 1 watt ono ae ine) ti dune eto sod @) wan m8 ies omen in) si aes ° oka x 6 aw Tio Distance Flan Reeng to Fue 188, mrstaton bas 4 eng dines wht roe ston Te eae be ase ie Smvottesaten oth Pa ce Wie iceaceeniccase LS 519 Toned Poionlg HP Nod Soutacceoneana Goel nee ese L = aghfthe sem ond y= leh ost (0 athe tainat set eaten Grewal ateoqal i 1 02 3 7 os Gietpaan (29 ie ‘7 a. ‘where L, = station length, m (ft) | a "A common transpoct system wsed on manual assembly lines isa constant speed $ 3 a corseyor min Fe 108 Bs rt ae ached ote Dg te a i $ an cosine equal ote cine Te Ts prover const od to 8 8 ee ‘fi pr edi haa para eran teh cmegor dag tii sen i 7 = ted au mananed rogoet he ne. The ole alte po 7 = ae ett ote, 5 q os 1 a oi owe la «sayan (Chap. 15 1 Manvel Assembiy Linge Ache Flew 188 Continuously moving conveyor feeding work units pasta workstation hete f= feed ate onthe ln, unitstmin. A constant feed sate on constant speed con. ‘veyor prides a cenlercocenter distance between base parts given by pe grie (182) where 5, = cenler-to-center spacing between base parts, mipart (flirt); and ye velocity f the conveyor, m/min (Uma) As discussed in Section 5.13, pacing with margin i a desirable way to operat the line so as 10 achieve the desired production rate and atthe same time allow for some product-to-product variation in task times at workstations, One way to achieve pacing ‘with margin ina continuous transport system isto provide a tolerance time thats greater than the eyo Ge. Tolerance time is the time a work unit spends inside the boundaries of the workstation It can be determined asthe tength ofthe station divided bythe conveyer velocity, thats, & 523 sohere 7, = olerance time, minfpar, assuming tata station ents are equa. stations have different lengths, identified by Fy, ten the tolerance times wil dtr proportionally, since yi constant “The total elapsed tinea work unt spends on the assembly line canbe determined simply asthe length of the line divided by the conveyor velo Iti algo equal 1 the sum of the tolerance times forall stations. Expressing thse relationships in equation form, dn (329 where ET = elapsed time a work unt (Specifically, the base part) spends on the con veyor during is assembly, mi, Ifal tolerance times are equal, then E i, Manning Level. ‘This was previously defined in Section 1323. For a manual sssembly ine, the manning level of workstation , symbolized M, ithe numberof work cs assigned to that station, where = 1,2,...." and n = number of workstations on 40 155 / Other Corsiderations in Assembly Line Design an ne he ets whe: = 1. Is wee pn shar otmp nna oen onto saw a Mulgan ef the ty ners ae gh tu tno tne everson eared The ote mange Shuma en es singel ee ef woe oe ay mtr fat wet (325 he M = rage lf ei wet = mie oe seit au une ofan one Tr weniger pets te ht batman ent ins ox nae me wee ne Angel eon, et asap vapor Tew eal eos seth oo. At dcr mS ey se at ass ose ‘Tcweans att ant) eg ator la oe truism ty) ral ings (0) cha Repnng Eon (2 yoke 185 OTHER CONSIDERATIONS IN ASSEMBLY LINE DESIGN ‘The lin balancing algorithms described in Section 153 are pevse computational pro- cedures that alloeate Work elesents to stations based on determinisi quantitative data, However the designer ofa manual esemby fine should not overlook certain ater fac tors, some of which may improve line perfomance beyoud what the balencing algorithms ‘cen provide, Following re some of the considerations. «+ Line efficiency. The uptime proportion B sacral parameter in asembly Line ‘operation, When the entire line goes dova, all worker are ied. It isthe respon sbily of management to mintai a value of Eas clase to 100% as posible. Steps that caa be taken include (1) implementing a preventive mintennce program to minimize downtime occurences, (2) employing wellrained repair ecews to ‘quickly fix breakdowns when they eecu, (3) managing incoming components so that pais shortages donot eau line stoppages, and (4) insisting onthe highest ‘qulity of iecoming paris from suppliers so that dowatime is not caused by poor ‘quality components. + Methods analysis. Methods eaalysi involves the stody of human work actly to ‘eck: out ways in which the atity canbe done with Iss efor, in Is time, andaa (hap. 15 1 Manual ASSembiy Linas with preter effet. This kn f analysis isan obvious step in the design of ama, ual assembly ine, since the work elements need tobe defined in arder to balay the line. In addition, methods analysis can te used after the ie iin operation tg examine workstations that urn oat 1 be botleneck. The analysis may result in improved efcenoy of workers” hand and body motions, better workplce laos, design of special tools andor fixtures to faite manual work elements, or even changes i the product design for esicr assembly (sign foe asembl i cused in Chapter 2) Shaving work elements besseen mo adjacent sation. Ia particular work clement results in a btteneck operation at one tation, while the adjacent station bas ample idle ime it mgh: be posible forthe element toe shetedhezween the t80 statis, perhaps alternating every other cycle, Changing work head speeds at mechanized stations, At stations where a mech nived operation is performed, the power feed or speed ofthe process may be increased or decreased to ater the time required to perform he tsk. Ifthe ‘mechanized operation takes too long, then an increase in speed or feed i ni cated. On the other band, ifthe mechanized process i of relatively short dura. tion, so tha idle time is associated withthe station, then a seduction in speed andlor feed may be appropriate. The advantage of reducing the speeded com binacon is that to! life is increased. The opposite occurs when speed ot fed is increased, Whether speeds andlor feeds are increased or decreased, procedures must be devised for efficiently changing the tools without causing undue down. time on te inc. reassembly of component. To reduce the ttl amount of work dove on the reg Tar asenbly Hine, certain subasemblies can be prepared offline either by another assembly cll inthe plant or by purchasing them fom an outside verdor that, alizes inthe type of processes required. Although it may seer ike the work is simply being mote from ove location to another, there are some god reasons fo ‘organising asembly operations i this manner (1) the requited proces ay be di ficult implement on the regular assembly line, (2) task sme variability (eg for adjustment or iting) forthe associated assembly operations may result in a longer ‘overall ey time if done on the regular lne, and 3) an assembly cell setup inthe ‘plant o bya vendor with certain special capabilities to perform the work may be able to achive higher quality Storage burs benween Stains, storage buffer is a locaton inthe prodetion line where work units ace temporarily stored. Reasons to include one of mare stoe- age butlers in a production fine inca (1) to accumulate woek units between to stages ofthe line when their production rates are diferent, 2} to smooth produc ‘ion between stations with larg tsk time variations and (3 ‘o permit continued ‘operation of certain sections ofthe line when othr sections are temporaiy down forservice or repair. The se of storage butlers generally improves the performance othe lne operation by increasing line etcency. Zoning constrains. Ys addition to precedence constraints, there may be other restrictions on the line balancing solution, Zoning constraint impose Fittions ‘on the grouping of wor clements andor their allocation to workstations. Zoning se. 185 Other Considerations in Assembiy tne Desian a5 constraints may be postive or negative. A postive zoning constraint means dat certain elemens should be grouped together tthe same workstation if posible Por example. say panting elements stould a! be grouped together de tothe need for special enclosres. A negative zoning constraint indicates that certain ‘work elements might interfere with each other and therefoe shoud not be lo- cated near eachother. Fr example a work element cequiring delicate adjustments should not be located near an assembly operation in which loud sudden noises cea, such as hammering, Parallel workstations Parallel stations ae sometimes used to balance a production line. Their mest obvious application is where a particular station hasan unusually Jong tat tie that woud cause the production rate of the line oe les thn that require to sats product demand. In this cast, to station operating in pale snd both performing the same long task may climinte the botlenec. In other situations, the advantage of asng parallel statins is notes obvious, Conventional Fin balancing methods, such the largest candidate rule, the Kilbride and Wester ‘method, snd ranked pocitional weighs method, donot consider the use of parallel ‘workstation. It tums out thatthe only way to achieve a perfest balance inthe ea er example probiem s by using paral! stations EXAMPLE 155_ Parallel Work Sstons for Bottr Line Balance (Cana perfectline balance be achievedin Example 15. wing parallel stations? Soluion: ‘The answers yes. Using a paral station configuration to replace pasion 1 ‘and 2, and reallocatng the elements as indicated in Table 111, will achieve a psec lance. The solutions illustrated in Figure 159. ‘TABLE 16.11 Aceignment of Wok Eloments to Stations for Example 155 Using Paral Workstations Staton we 06 2007 = 1.00 on 100 i 2 ow 1006 Conap. 15 / Manus! ASSemby Lines, ston 3 8 feenteees Sesion} Sunn svi Bevan |_| Bena ‘ew — Bers [>] init ® Figure 159 Solution for Example 15 using parallel workstations (a) precedence Aiagram and (b} workstation layout showing elentent assignments. Work content time Tx ® 40 min asbefore. To determine the avaiable tn, aot that thee ate two coareational stations (and) wih Z ‘each. The paalle stations (1 and 2) each have service times of 20 mi, but ‘each s working on its own ait of product so the effective througpet of the two stations is one work unit every minvte. Using this reasoning, th balance efficiency is computed a5 follows: 18.6 ALTERNATIVE ASSEMBLY SYSTEMS ‘The welldetined paco of & manual assembly ine has merit from the viowpoint of ‘maximiing production rate. However, assembly ine workers often complain about ‘the monotony of he repetitive asks they must perform and the unrelenting pace they ‘must maintain when a moving conveyors used. Poor quality workmanship, sabotage of the lie equipment, ead other problems have occurred oa high production assembly min see 156 / Aerntive Assembly Systeme “ lines, To adress these issues, alternative assembly ystems ere available in which the work is made less monotonous and repetitious by enlarging the Seope of the tasks performed tthe work i automated. This section briefly discusses two alternative a. sembly sysiems:(1)sngl-staion assembly calls and 2) assembly work cell consisting ‘af worker teams and multiple workstations. ‘A singl-station assembly ell consists of single workstation in which sembly is secomplished manually on the pradut or some jor subassembly af the produc, This, method is genorally bed on products tat are complex and produced in all quantities, sometimes one-ofind. The workstation may use one or more worker, depending on the sie and complexity of the produc, variety of worker skl required, and te produc tion schedule. Custon-ngineered products such a machine tools, industrial equipment, models of complex products (aera appliances, cars) se assembled lls Assembly cells consisting of mukple workstations and operated by worker teams are seen as amore rewarding Work organization competed to the pacing that occurs on ‘most manual asembly ines Instead of the straight line ow typical of «conventional assembly line, the cel soften Ushaped. This layout alls for improved interactions and teamork among workers. The pace ofthe work is controlled lrgely by the work: ‘er raer than by a pacing mechanism such sa powered conveyor moving ata constant speed, The numberof asembly task asigned to each wosker i greater than ona cx: responding assembly line. The work i therefore les repetitious, broader in sope, and mae rewarding, Because of this job enlargement, fewer workers te needed inthe cell ‘and les floor space i required. ‘Other ways to organize asembly work by teams iniude moving the product ‘through multiple workstation, but having the same worker team follow the product om station to station. This form of team assembly was pinoered by Volvo, the Swedish car rake, It ws independently oporsted automated guided vehicles (Section 10.22) that bold major components andor subasemblies ofthe automebie and deliver them to ‘manual assembly workstations along the lne. At each station, the guided veice stops at the station ands not relesed to proceed uni the assembly tsk at that station hasbeen, completed bythe worker team, Ths, production satis determined by te pace af he team, rater than by a moving conveyor. Te reason for moving the Wock uni hough sulile stations, rather tan performing al the assembly at ove lation is because the ‘many component pars assembled tothe ear mast be located at more than on station. ‘Aste car moves through each station, pats fom that sation ae aed, The dference betwen this andthe conventional assembly ine is that all works done by one worker team moving with the cr. Accordingly, the members of the team achieve greater pe- sonal satisfaction at having accomplished! a major prdon ofthe car assembly. Workers ‘on a conventional ine who perform a very small portion ofthe total car assembly donot ‘sually hae his lve of job sation, ‘The use of automated guided vehicles tons the assembly sytem to be configured vith parallel paths, queues of pats between stations and other features not typically found on a conventional assembly ne. Tn addition, these team asembly syste can be designed tobe highly lesb and capable of dealing with variation in produ and or responding variations in assembly cycle times atthe diferent wosksatoes, Accordingly, this type of team assembly i generally used when there are many different models to bo produced and the variations in the model result in significant diferences in tation service times,ae REFERENCES Chap. 15 J Manual ASEM ing Reported benefits of worker team assembly systems compared 10 convention, sembly line incude greeter workstation, beter product quality, increased cape bility to ccomamodate model vavations, aad greater ability to cope wih problems the, equre more time without stopping the entire production line. The principal diadran ‘age is that these team systems are aot capable ofthe high prodotion rales characteris ofa conventional assembly ine. ‘Another alternative assembly sistem is automate assembly, coveredin Chapter 1, ‘whic includes hybrid assembly systems consisting of bath ufomsted tations and kumay assembly operators, (1) Avonovsss, M.S, Kanes, aT, Line, Dee for Asembly, IFS Publican) Lid, UK, an Springs Vel, Ber, 863, Bago, 1 E.M Das and A. Sie, “An Anata Framework for Sqpeng Mid Mosel Asenby Lies," neraaona! Journal ofPaduction Reach, Vol 30 No.1, 1, mp3 [9] Booranoro, G, % Downunsy, and W. Kova, Poder Dein for Monica ant -Assembiy, Mago! Dees, Ine, New York, 194 [§) Beas, 6, Hundboot of Product Design for Manfctrng, Grew Mi Back Compa. New Yor, 1585, Caper [5] Chow, WAL, Assombp Line Dain Mahadsegy and Appaions, Mace Dee, New Yor, 95, (6 Dates. E44 and ¥. Cons, “Assembly Lie Syneaing for Mol Mi" Iisratnl Joaral Production Resaeh Vo. 1B,No.5, 175, op. 6-47 [7] Data, EM, “Mixed Model Assay Line Sequencing Problms” OMEGA, Vol 6 No.4, 17S, 313-38, Daxei, EM, and A. Nemo, "A Med Model Sequacing Appin” nerntions Souna of Producton Research, VOL 19, Ne 1,8, pO. (8) Devrscs, D. Fy “A Branch and Bound Teshngue for Mined-Model Adembly Line Balincng," PD. Disenaton (Unputlshd) Aaen Ste Univer, 11, (00) Pemvevoes, C.J. L, "Meursti Method fr Mixed Model ssl Live Balasng and Sequencing” MS. Thess apublea), Leigh Univers, 182. [tt] enasus, 5.1, and M,P, Groaia, “Mixedmodel Asemtiy Line Balesing std Sequencing. A Survey,” Engine Deion and Auiomaton, Vol 1, No.1, 1935~ posit [02] Groover MP. Fundonenul of Modem Monyacurng: Materia, Proves nd Sten, ‘thes, Joa Wty & Son in, Hoboken, N.2013 lis] Hevesos, W. Band DP. Boo, “Assembly Line Baling Using Ranked Poston! ‘Weight Tecniqn," Journal of ida Engicrn, Vo. 12.No. 61, pp. 39-298 (04) Homes T, “Assembly Lino Balancing A Set of Changing Piclens” Inertia eural of Production Research Vl 8 No. 1015p. 107-181. (05) Hounsuen,D. A., Frm th America Smo Mee Production, 100-1932, The Jobs Hopkins Univesity Pres, Baling MD, 184 [06] Hee, N. L, nd U. Wauseon, Reorgening the Facone Competing trough Caller Manufacring, Poot Pres, Porn, OR, 202, (U7) Towns, 1, "A Review of Ascombly Line Balun” Journ of Indi Eger, VoL 16 No.6 1965 pp. 24-282 2 9 feviow Questions 4, (8) Krauces, Msn Win LA HewritieNGthd of Ase Une Bani Ju oft Exring V2 8. 86g 32 BE 9] Naas, J. LC, “ote Lise Bales fo Mico Tne” Manage! 7 Science. Nol. 19,No. 4, 1972, pp. 423-434, = (20) Mors, C Land Youns HH, “A Here Mato of Astly Lie Ralang fo Asim of Cente Vase Wot lees Toe nwa oy bce Eger, Vo Ne 15 pp 2528. (t} Now. ¥5 WE Wank, ed HS. Waser, nl Asem, Caps & Hl tend, U1. (2) Proms. 0. 7, Toro, anon and Tea i Ase Sse, Hajek Bok Can a, Resa Push, 199 (5) Ramat, 8 ad A, Datars, Avent Line Ds The Big of Mito ytd Asi nsw Gone Aah Sings eto Lenn ne UK 2 (24) Sica RT. RRs aed WTA Cmte Amol Soe fo Nae Mosel aseniy Lins nt intine Probie Stn” netted Seunal of Prin Rear, Vl SN 1 92 pp. Le [2] Vas, C, “Mut Profs sent Line Beng” PAD. Dsrtion (Ueld) ati of Peis (2) Woes, Maha seb, xb UnvesyPe, New Yu, 204 (7) Wu, R Mas Prin anger, Wy & Som Ladin, UR 2 ‘REVIEW QUESTIONS. ASA What are the for acts tha othe oe fans nes? 152 What ae the fourreasons gies inthe txt tha expla why mana ase reso odusive compare to aerate methods heh eupe wars ech peor allot the tas fo asemble ie product? 153 Whatisa smu aan Uo? 154 What do the ems string and locking mea? 18S Idea an riety desi te three major categories of mechani work cept ee- teas used in prodoctin Hines. 186 Tooope wih prot vay te yes ssemBly line ae detribdin he et Nee the the tesa expan the deren beaver the. 187 What doesthe tee ine ein mena ia production ie termiology? 158 The tect micimum amb of worker onan stem nthe mii inte hats reat tha the rato of ha wok cnet tine Ty dvisdy he tine T “eo ctor ae ident inte oh me fiat to store tis vale ia pracice Name thet factors 159 Whats the ditference betwen the yee sine T andthe svete 7.) 1510 What isa minim rina work element? 1841 What ismean! bythe em precdence conan? 182 Whatismeat bythe term balance efleny? 3413 Whatisthedifeene between ow he hres anda rule wok enc how the Kibrige and Wester metbod work? 1814 Whatismean’ byte term manning ol inte cone mal elie {SIS Wistarestorape buffers and why ar they sometimes wed ona mas sembly ine?‘PROBLEMS (chee 16 / Manual ASS Lins Ansnerstorblems abel (Ayn sein the ayn ‘Analysis of Single-Modiel Assembly Lines 181. (A) Annssl demand for # now semble producti expected tobe 75000 uns. Wik ante tme fer the prodet #288 min. The scent lne woeks 50 whi, bn Expected lin fens 95%, Wih one worker er stabon,dtrtn (2 ge ely roction te () ex time an () el mina nbero work 9 52 A newpct tobe stemlled on a manual assembly. The in tobe designed o proce 10M unis. Work content tine fr ths ped 37 me. Te amb oe ‘ellopecie 5 mk, Sabi, Shit Espero line ecencye66% There be ‘ove worker gr stton, Determine (a average hourly produto ate, (8) feline ane (@ idea) nium umber of woisaton. 183 Aprecct whore wok content tine = 2.0 mia stobeassenbledana manual protacton line Require procution rate 3 oni From prsiousesperinc, its xmas tat proportion uptime ~ 005, bale eliincy = 83%, snd Tepstioning line = 6, Desermie (2) os ine, (0) eal mine mune of workers equied on the ne (@) more ets estnste ofthe aero workers on he ine when preporion unin, Tutanoeeffseny ard reposting tie ae acount fr. 164 Amunsl scl nha 20 workstation an peodoes 4 unity won operate per ‘aon, Work content tine to semble the posit = 4. min, Proportion uptime = 084 tn epstning tine = 9 sex, Determine he bance de 185 Amansalasonbly ine musthe ded fraprodet wth annul Send 95100 is, ‘Work content tne = 450 min The fine wil ave cnc worker pr ain and oper ate $0 wh, shift, an 75 it Wook unis wil be atached oa continues roving conveyor, Estimate Ine efieney = 087, tluncingefirey = 092, and ‘posting een = 085. Determine (a) howl podoton ete to mest dead nd) nunberof workers quired. 156 A ingle mode sembly Hines eng planed to produce consumer applic th at ‘of 1p ait. The ae wil be operated 8 ut, 2st pr dy, 5 daysvk, 52 wee, ‘Work conta ine = 35.4 mi Fox plang purposes tis amiatd dae peopston ‘uptime o the Ene wil be 95. Determine (0) average hours produton rat, 8) ee ‘ue, and () here minim ber of workers eguied on te ine.) theta ance efiieney 09a the reponing tine » 6 see, how many workers Wil actualy ‘be requted?() What sth asembl ine abr leney? 187. Required production ae for + new produc i 45 wits and its asely work cme (eat ie ir 125 rt wl be produed onan asembly ie that sles fou autoated ‘rksaion,Becase of he aulemted ations, the ae wil have an execed uptime ‘ney = 90%, The remaining manna stato wil each hve ove works. isan plod tat ofthese ne wl be oa ce to epasitning the btTanek sation I fhe bans dee expected abe 7, etre () he ese (D) oer owe 15 and (¢)ssembly ie aborlciency onthe ie 18S A final asembly pln fo anew automobile ode ito have a capacity o 180000 sn nly. The plat wil operat $0 ny, 2s, day 75 eit. ele vided to thee departments (1) boy sop, (2) pit hop (3) general sem dpa ren. The body shop eld the ca bo ing obs, sd the pa shop cash bd Fes Both ofthese departs ae highly automated, General seal as automation ‘Thee se 15D of wrk conte ie oa exch ainths third department, where casa moved by a coninuoue conveyor. In 2dton to the workers aserbig the pol on thetinein general ase, thr are 25 ly workers, Deterie (2 hou production > phe an rate ofthe pnt) mmber of workers and workstations in general sembly, given tht its manning vel 824 talancing efficeney = 9%, proportion vie = 95%, an a= stoning ine of 15 mins allowed fr cach worker. (¢) Whats the smi En ber cine in general aseby? 459 (A) Production rat fr certain smb prod i Sans Te esol wr com: ten tme » 35 mn. The ne operates at 2% opine Ten workstations ave no workers “enopposte se of thine ott both ies ofthe product an be wrk on sian ‘uy. To remaining sation ave ore worker. Repesioning line lot by etch worker 15015 mney. is known hat the numer of workers he ine to more than he runber segue for pect base. Daring (a) numberof nts (8) numberof Workstations 6) ali efisecy, an (0) average manningee (eee uly were). 1510 The work cotet ine s0 info aprofuctasembed ona mal rogutiontine, The Tne usesanenechead conveyor hat moves t 12 mina Thre ate 7 wotkeios on the line ose hr of which have vo woke theres have one worker each, Repost tine per worker &9 se and uping een 95%. (3) Ws! weal be the bousy ‘rodent the lin were pefely alto? (b tthe ata reduction rate 3 ‘Suni, hot the tleneefficiney of the ne? [) To compra fr sevice tine ‘ably, thas ben decided tha the toerance me shoal bo 30% preter thn he cde time To achieves, wht station nah soul be wsedon he line? (3) Detre the eaped time tat xc te part spends on the proton ne? ASI The proton rae ofa mans ase tne 38 unt. The wok cote: tae ofthe roe ide on th ine 248 min. Work is ar atc ta vig coneyr whose Sood = 1Sm/mnin Repstosing tine per wesker sein elfisone 95%, onda ing eves 125 (gnering sity werk) Ong impel te weber ‘others ended nie ine sabot 1% moretan th amber egued fr pestle. he werstans are arangedina esd the engi af ach aia 35 (6) howlong |i eae producto in, and) what she apse te bate at pends onthe ine? Line Batancing (Single-Model Lines) 1512 Stow that te wo stemeats ofthe ejoctve fin in sage mode ine blacing in uation 15.20) ar equal ‘5 1543 The ble below defines he precedence elatonipe and elemest as fo new mode toy. (a) Contra the presodeac dagem fortis (6) Ideal tine = 1! rin ‘epostienngtine ~ 01 mia, abd uptime proportions asa to be LD, what the th veil minima murber of workssns eguied 2 mine the alae iy undet he ssp that thre wll bone note eration) Use belgesel ‘oasign work elemento sans (@) Campus he lance ds or Sor sition, ‘remediate WorkElement —Tefmin) ——_Predocassors 7 2 1 3 1 4 2 5 2 8 3 7 45 8 35 8 18 0 a8sit asus 1816 1su7 of5i8 19 (Chap. 18 F Manual Assembly Ling (A) Soe he previous problem sng the Kbride ad Water method in pat Soe the peso problem sn th raked postal weights method pat (6), ‘A san sey Hie 0 be designed to make asl consues product. The wo ‘eneots, bine, and precedes constraints ae sven nthe tbl below. The we sil operate te line fr 400 in er day and ms reduce 30 prods prey ‘Aechansed be mong ata pee of 125 ita, anspor the prods Deve, fttions.Becase of he vary in the ne rquved 0 pron t= sembly opin ‘ons, it hasbeen deter tht the tirade sald be 1 ins the le ting ‘of he ne. (¢) Deter th ea minima aur of workers on teh. () Us che Kilrdge nd Wester tho to alas he lie () Compt the bal selina pat) Element Time Te Eloment Procededy Tine Te 6 damn 1 04min 2 OPmin 7 amin 4 2 05min 8 osmin 4.9, 4 0Bmin 2 8 03min 5.6 5 2a 08min te Solve the previous rblem sng the aed positonl weights methodin par () (A) Amana ace line operate with mchuiaed conveyor Te conveyer move sta sped of 5 fini, ad he sing between tase pts hued oto ein 4 Tih been determined thatthe lin erates best when there i one worker er station ‘death tation 6 Jong. Tete ae 4 wer ements hat ast be aca omplcte these, and the element tines and resdeacerequiements are Iised inthe table below, Determine a ed sean cntsponing yee ie, () tern time foreach worker, a (ciel minima mer of woken he ine. (8) te prasidene gram fo th problem.) Deleine an isnt ie balancing sluton (For your slaioe,dtcraine te balance del Preceded by Precedediy | Element 7 Oana 3 Oamin = 2 05min = 9 amin 5 2 o2min 1 03min 7 4 06min th Otmin 5 atmin 2 2 a2min 8,10 6 02min = 3.4 | 18min 7 Oamin 4 Mo a3min 19 {A now salle appliance 10 te asendled an a single-mode! assembly i. ‘Te line willbe operated 2 day 8 hla. Th wrk neta as bon died ine ‘work element at eefied in he flloning able. Als glen ae the elena ties ad ‘rcedeace eguiremen's Anal pocucton sto be N00 ints Tis anise hat {hein effin wil e096 Reposoniag ne fo each worker 008 mia, Determine (jh avers hourly rods ate) eo une, 3) theoreti isa romber oF ‘workers read te meet ntl production requremeats (0) Use one tein babe ing slgoritmstoblane the iF you solution, detec) ean fine and (Covel iebr eine om tein poten Esment i, Element Desstpon 7 Pace! “ean workhoke” a elamp as 2 Assemble onto motor on | 3 Assemble racket Ato frame ez 4 4 Assume bracket 8 to frame an 4 5 Assemble motorto frame as 2 6 Afiinsulainto bracket A an 3 7 Assemble angle plate to bracket A om 3 8 Afxinsuiston to bracket 8 an 4 9 Atechink bar to motor and rocket & om 45 10 Assemble he wires to motor uss Assemble nameplate to housing ane 12 Assemble ght four to housig an 13 Assemble ade machanism to fame as 6,789 14 Wreswich, motor, and ht on wn 18 Wire blade mechanism to sich 0 3 48 Atschhousing over motor os ow 7 ——_Testbiade mechanism, ft ot. ae 1518 1 —_Afiinstucton label to cover plate az - 19 ——_Aesomble grommets power cord am = 20 Assemble oordand grommet coverplate 023. 18,19 21 Assemble power cord leads to switch om 20 22 Assemble cover late to fame om oa 2 Findlinspectandromove om wodholdor 025 eee we Workstation Details 1520 (A) An orcad cominuis conveyor is wed 0 amy dwar base pe cong & tana tembly ne wile components ze bel el to them Te spacing between spans = 22m and he ped of he conveyor = 12min, The gh ah nk ston} Thre oof 5 statis orf whichhae tw workers: hear alo thee vidi woekon sign tothe ine Deteine 2) qu tine ad eed, (tance tne, (© mating es (0) elapsed tinea dbase bse part spend once. 1521 Ameviagelineisusdtoaseniesprodact hoc ork content= 2 mi. Production tate ~ Suni, end the proportion spine = 0.6. The leeth of ech satin = 20m + and tain nasi lvl = LO for alstatons. The bel ped ca bo stat vl be- wen 6 0430 nin is expe thatthe balance delay willbe about 0B or sigh higher: Ti torreon exh jesse a) Deere the und of stations rede on ine (Usage tie tats 0% seater tars th ec ine, what ‘wold be n appropiate belt sped and pacing between pas? 1822 he gone sembly department ofan aatomobe Gal asenbly plant, there are £95 welts, nd the fle ne = 93 min. each worst 62m ong, aot the olan ine» thee, termine the along (2) speed of he conveyor, (@ cenersocenter spacing heteen unis op the ie, () wi length ef the general sembly ne, asuming 0 Ycat space between sions, nd) eps tine a work unit ‘ponds inthe general ase partment 1823 Total work cemeot for product sstembled on 8 msn poduton Hine i 30 ia. Prodan rao the no st 7 uni. Bab pat ae attached to a moving con veyorwhoe peg = 22 iin, Repesitonig tine er worker is6se,andlineeficency(chap. 16 / Manus! ASSeMbiy Lines ‘94%, Due co pertet Ene bling. the numberof workers needed on he oe ag te wa morewerers th the mmberegied for erect balance. Mancingletel = 25, ‘eng sity ust: Determie (the BUM e. tkes and() th rane of ‘workin th ine.) What ithe ale fen fr ths ine? (a he wore ows ae asnged in a ie, and the leopsh of ach ation is 32 my, what isthe tke tien each staton? (e Wha th elagnd ine 2 Wok uni pends onthe ine? 1524 A muna asembl fine tobe dsiged for a eran msjor apliane whos sembly ork conten sine = 20boure. Te Bie wl be dious fran annul production ne ‘of 1090 ants The plant wt peat one shi pra, 20 ay. comics ‘enveyorsstem wil Be wed and wl operate at 2 speed = 16a. The ine must be designed under he following ssampton blac delay = 6%, ple ese = 9%, ‘positon ine = 6 se foreach worker an verse manning vel = 125.r0tcau ing uty workers () How many workers wl be requied o operate bear ine? eh tation 20 mong, (b) hom ong wl the produto in be ee () wa he laped ne a work unit sped he ae? Batch: Model and| ced Model Assembly Lines (Appendix 15A) 1825 Twaprodus ate tobe pode o abutc-aodelasembiy line th wil opr ek snd 0 wey one ofthat ie mst be dorado product chageovesberneen es “Ano dead (Dg) bate quate (Q), wrk content tine (Tug and changeover ie (foreach prod acl inh ble low, Th stiapated line efiieney = 07, tulinse eticiney = 095, and reposting, tine = C2 mp. Deternine (3) number of workers on the Bn, (8) prdeton ate fo the op, end) he podaton Shed forthe td) Coal the amber of workers We reduced ihe bth ses are doub Iso, by bow many wore? Produ Oy ng Tos A 16000 860i Sr B 2000 100 39min Shr 1826 (A) A batchaodelasembl line is boing planned to produce thre ple power tools dil a sande, and & jig san: The tree mods wl be produced in bacbes tecaee ann demand foreach power too 9 sficieat to emplay 2 ie fl ine foreach, Tite to changeover th fine betheen producing rns ig. The ne wi op erate hn, $0 whi worker per sation. Data on wodk conten ine, eye ine, ‘ad anal demand ae preseatd in the able belo. Estimated ne efseney = 095 and ‘hae efiney = 05, Repeioning tine per wrker = 9 sc Buches af each owes {wale paged 10 ney, wih teh uanites proportional nmualdemand fr cach pact Deteraine() the ruerof worker onthe ie, (9) the prodctio rts forthe hee prod, and (the prod scot or the yea. Product Work Content Time Annus Demand ‘ADA Bina 30000 BSender ‘emin 18000 Ciigsow Zin 12000 1827 Twommadeh, Asad Bacto be prosedonamixed model sembly ine bt operates 209 Ir Anal demand and work content time fr mel A ae 2400 unit ané 20 min Plobiems 1528 1529 1530 18H 188 4 425 respenively, an for model Bate 4080 and 2L0 min, Line fficey ~ 095, bbace ‘cen = 093, repiorng tine = 10 mi, and manning eel = 1 fr al aons DDtemise how muey workers mast be on the production Sein ede to pode tis vwrtoad (A) Ths models, A,B, and wil be peoded on a izod model arbi ne, Hoary production ate and work ome tne for model are Osh a8 450 minor moe] areas nd 35 0c and for ode Care 30 itv a 250 rin Line eens 1595, blance clin is 54 ropostonag fcieney ~ G3 a mann lve! = 13 aterine how many water and worsations mit be on the pofuton ine nado o produce is werk, Fo Problem 1827, determin the varie ae lachig ear for modes Aan Fo Probes 1528, determi the vrai tt huang inter for modes A Band For Froblem 1527, deine (x the fed rate lacing itera, od (6) the unc sequence ofmdel A and B daring! brfprodasion. For Prolem {528 dexmine (3) the fed rate tering internal, ad (the lurch sequenc of model A, Bs C ding ib of rodion ‘Twomodels, A apdB, ato be asembled ona nlsed-ndel ie Hos roduton ates forthe evo model are A, 25 unis, and B 18 en, The work elemens, element ‘ies, and precedence egies are gin the table ek, Elements Gand 8 not ured or ode ,anelenents 407 ae a required for motel Assine £ = 1 ,= 10 and f(a) Const the precedence diagram fr each node aa or both ve combined it one igri, i th tori mina amber ef worst. tins requ to achieve the eq procs rate () Use te Kile ad West atone ac olen (Deri ia yer ‘eluonin() Worsiementt Tem -Preeededby ‘Tag __—_—Provadedby 7 temin Os nin - 2 o3smin 1 o3min 1 2 arma 08min 1 4 osmin 2 - = 5 tamin 3 13min 23 é : a amin 3 7 osmn 45 - : 2 - "| aria 56 8 osmin 7 O5min 8 Toe 42min “5min Fer the data given in Problem 15.38, seth eddie aac problem ‘op we the ranked postional weighs method to etre he ede of ety of work cements ‘Tree model, A,B, an, a0 be aenble ona mized node ae, Hoa production aes foc th hee mls ne: A, [Suns B, Deo, nC, Stee Tae work men elec tims and precedece eqiemens ar gven nthe folowing table Asune B= 10,E,= 10,an0 Mf = 1 (3) Cons the pesdens tinge fr sch model nd {oral tee modes ombind int oe dig. 2) Find the theta misioum nber of vorkstations ree to ache th eqaed production ae. Use he Klee ad ‘Wess ret tose te ine bain rable (2) Determine ace te or the vohtonin (0)(hop. 16 Manual Assembly Lng Tou __Pocededby Tomy Precededby Teen 7 tenn min 6nin 2 osminy 05min 2Smin 1 3 O9min 4 08min 09min 1 4 2 05min a 5 - - osmin 1 6 o7min 2 o7min 2 o7min 2 7 tamin 3 13min 3 tama 3 8 - 09min a a : : tamin 5 0 osmin 67 OBmin 618 OBmin LTS Tre 48min 62min 65m 15.6 For the dats gies in Probl 1535, (a solve the mixed model ine talaning role eg tat ine fcency = 096 and epson etcleney = 095, Determine the balance effceny for your soaion. 1537 For Probes 13.35, determine (a) he ised rte unig interval a(t the une sequence ofmadels AB, sd C ding hy of prodaion. 1538 Two simiar model, A and B, ae tobe produced ona xed mode asl ew, These stefour vorkersnd four stations on thine (= Ilri = 1,234). Howry production rates or the wo models ae fr A, 7 anit and for B, wits. The work element, element tines and precedere reguremons forthe two model are gen inthe tte telow. As the able indices, most elements are comin o bck pie. lement $i, ‘nique tomedel A, wile cements 8 and9 ae wrique to mud B. Assume Z = 1. ard , = Lia) Deveog the mixed-mode presdeace agra foc th wo model 86 fe ‘oti mode combined, () Determines ne alan staat allows the wo mel tobe produced on he fou tations atthe speed rates (2) Using your sition rom tobe the fed rte model acting poblem by detrmiing the fed rate nein i ‘ey pd consretng aaa tose he sequetce of mal achngs uring the WorkElementk Tay Precedec by Tamy_—_—_—Preveded by 7 Tin Tria 2 amin 1 amin 1 a mn 1 in 18 4 amin ~ 2min ‘ 5. ima 2 . : 6 amin 234 amin 234 1 Smo 5.8 3min as 8 : : Amin 9 2ein Tre 16min 2imin APPENDIX 154: BATCH-MODEL AND MIXED-MODEL LINES “This appendix explores some ofthe approaches that cam be used to plan and analyze bateh mode and nied-model assembly ins. _Ropendc 8A / Baeh Mode and Wines Model Lines a ‘6A.1Batehr Model Assembly Lines ‘A batch-mode production line (BMAL) produces different products batches. tis ap propriate when produc variety i too great forthe products to be produced on mised. ‘node tne. Is isadvantage stat downtime occur when the line is changed over from ‘one product tothe next. On the othe hand, tere must be some siilaity among the produets or it would make no sense to ry to assemble thom onthe same bas ne. ‘The equations developed in Secon 152 to analyze a single-mode line can be ‘lated forthe BMAL. To determine the average production rate forthe line based on annual destand, te sum of demands forall of he products tobe made on the ines used Sow (sa) ere Dy = demand for product, units, and the summation i cad out ore the amber of products tobe mado the lin and T= ttl dawnt during the year for cangeoversbotcen produ. Fro ths the aerge cc ine canbe determined from Bqsaton (352): 7, = €ODIR, where T,~ average jl me, milgcand Efe effin, Average inthis instance means the average ove the P produits made onthe ins, Te sverage service ini the eye in es the repstoig tine T, which a- sumed to bs the same forall statons and products 7,» 7 ~ T, Todetrmine th number of woken he ine, weighed worage ofthe work xn tent times we, where the weighing based onthe eral demands for each prod Minimum atop = — (15A2) whete 2, = anticipated line balance eficiene. If theres one worker pr station (pia), then Equation (15A.2) also gives the umber a stations. [Now that the numberof workers and stations has been determined, each product {wil be produced at its own service time and associated cyte ime and production rte ‘The service time for product j can be determined by rearranging Equation (1534) as follows: Tog ee (sas) here Tag = work content time for product j, minut. Thee, the cele time for product Ga G+h (a4) ‘The corcesponding production rate for product jis calculated by rearranging Equation (1: GE a ASA) ae (1545)8 (Chop. 18 / Manual Asem Lina, The follonng example illustrates the use ofthese equations as well asthe ieues of changeover and scheduling ina bath-model ne. EXAMPLE ISA. Analysis ofa Bateh-Model Asembly Line Two products, and Bare tobe produced on a BMAL. The plant operates 2000 bry, butte downtime between Batches s Sh. Annual demand, work ‘content time, and batch quantities forthe two products are given in the fo. lowing abi: Procust) —_Dyleniteye]_Taglin)—_ Giunits) a 20,00 20 2000 8 53000 no 3500 ‘The anticipated ine eficiensy ~ 96 and balance efeeney O84, ang epoiionng tine = 0. min, Determine (a the mumber of workers requires ‘on the line, (b) the produaton rates for zhe two products and (c) he prec. ‘ion schedule for the year. Solution: (a) Given the annual demands atl batch quantities, the number of batches (or changeovers resulting in dowatine) wil be 10 foreach product ora toa of 20 At 5 hr esc, that i 20(5) = 100hr of downtime. The total annual demand forboth presi 28000 + 35,000 = S8C0N. Using Equation (158.1, Average ope tne T= 60(096)2895 ~ 1.99 min, aie arciage seivke time 7,= 199-01 = 189 nin. The weighted average work content ‘ime = 36.36 min. The number of workers on the Hine is determined fom Equation (I5A2) 3636 Tas(098) With one worker pr station the numberof wakstationsn = 21 (0) Tae serve time for product A is Tq = 30(21 X 094) = 152 min. is cele time Ty = 162 min, and its peodvtion rae R,q = 60(0.96).02 = Sb unisihe ‘The service time for product B is Ty = 40/(21 x 094) = 208 min, its cyte time Ty = 213 min, and its production rate yy = 60(095)/213 = 09 units (Batch quantities ae specified the abe: Qg = 2,000 ane Qp = 3,500-The production chek willbe toset up the line for pce A (Sr) and produce the batch (2.003556 = $625hr) and then change ovr to produc B (Sn) and produce the batch (35002709 = 12920 br). This cyte i repeated 10 times during the yea. Toil time = 10(5-+ 56.28 + 5 + 129.20) = 1.9545. ‘This i aight less han 2000 br Because the numberof workers was rounded up from 2047 to. finimum Integer 0 7 rounded upto 2 workers Lt popondhe TBA / BatchM@oda! and Mixed Mode Lines a ‘The BMAL line balancing picblera canbe solved separately foreach product made on the fine using the same line balancing methods used for ingle model lines (Seton 15.3) Some atemp is usualy made to assign snr tasks othe same stations from one prod ct tothe net 15A.2 Mixed Model Assembly Lines Unlike the btsh-mode! line, «mixed-mode assembly line (MMAL) is capable of pro ducing variety of dtlerent product models simultaneously and comtinuoesy (atin bates), Bach workstation specializes inserts set of assembly work clements, bu he stations ae suliently exible tat they can perforate respective tasks on dierent ‘models Thi section covers scme ofthe lechnial sues elated io mied-model assembly lines, specialty (1) determining the numberof workes and other opersting parameters, (2) line balancing. and (3) model launching Number of Workers on tho Lino. To éeiermine the overall production rate on ‘he MMAL, Equation (151 is adapted inthe same way afr the BAL: 3, R (sag) SiS "Note thatthe denominator in this equation needs no downtime adjustment compre to Equation (154.1) because there is ao lost production time Between models inthe MMAL. The production rate of exch model can be determined from its respective d= mand rte: Da i OS Ha sary ‘The individual production rates wil sum tothe overall ate: : R= 3m (58) From his aerageprodction te, the aerge eye ine and average servic tine can be deteined for models produced on he ie: = 6OER, aT, = T.~ 7 Determining the umber of workers onthe lin is again based on # weighted sve age work content ine as fied in Equation (ISA) repeated here: Data /p eden Eyl, Tt prods rats fo exch model are knoe aber than anal demands, hen the nue of workers canbe determined sing Equation (1595 w = WLIAT, where workioad is defined as the summation of RyTy forall and ATs the avaliable tine per worker durog the period under consideration (og, AT = GDBE,E,). = Minium Integerfea one | om Boat a EXAMPLE 154.2 Number of Workers ona Mixed Mode Line The anavsl demand and werk content time for two models to be producee ‘ona mixed-mode assembly line with one worker pe sition ae given in he following table: Model) _ Dy uns) ia x eon «70 8 wan 0 Anticipated tne eflcieney = 095 and balance efficiency Reposioning tine = 015 min, The lne wil operate 2000 hy. Determine (@) the hourly production rat foreach model andthe overall produstion rate and (b) the number of workers onthe ine. Solution: (a) Howey production rate of model Ais Ry, = 80002000 = 4 units Production rate of model B is Ryy = 120002000 = Gunite. Overall production rate R, = 4 + 6 = 10 nis. (6) The weighted average work content tine by Bquation (ISA 2) 525.80 min, The average cyl tine i 7, = 60(095)/10 = 5:76 min, Average service tine 7, = 516 ~ 0.15 = 56 min, Autcipated balance ees is piven a 092. Using thes vlusthe numberof workers is calculated a 258 w= Minimum integer = <== — = 4.999 ounded up to S workers Minimum Integer = 5Topy = 4999rounded yp tS Mixed-Modet Line Balancing. Algorithms 10 solve the mixed-mode! tine balancing problem are usually adaptation of methods fr single mode! lines. The pret at treatment of this topic is ada limited. Mixed-model line balancing and is companion problem, mode! sequencing, i covered in greater depth in several of the tefeences indding (7) (2-23) [2] erature revew hee topes pe. seated in (11) In single-mosel fine balancing, work element tines are uilized to balance the ine, asin Section 153, In mied-modelasembly ine balancing, total work element times por hour (or per shift} reused. The cbjective function canbe expressed as Mainize AT WL) orMininie S(AT- 1%) (SAS) where w = number of workers or stations (again assuming the M w ‘AT = aval tine in the period of interes (eg, how, si), muafwonet WL = workload to be accomplished daring the same perio, inne; and 77; = total sevice time a station io perform its assigned portion ofthe workload min. ‘The two statements in Equation (154.9) are equivalent. Hourly workload ean be ‘aleulated by summing the production rates bythe work content tines fr al products: w= Ste (sa) ‘To determine tot sevice tims at tation Jit compute the total tine to perform each clement in the workload. Let Tye = time to priona werk element koa product). The total me per elements given By 7 T= Sit saty where 77; = (otal tne witia the workload that must be allocated to element & forall prodocts, min. Based on these 77; values, element assignments canbe ade to each st ion according to one of the ine balancing algeiths. Teal eve times at each station se computed TIy= 3TH (ss. foal servie ne at station wich equ the sum af the ns of the el ments that have been signed tha sation min “Meesues of balance effieny for mizedndel ase ne tlanig come- spond t thse in ngemodel line blaning, aciae wlio TT) where 2 =balimce een, WL = workload trom Eqution (5A.10), miss ‘w= numberof workers (satin); ad Max(77.) = maximum ve of ol series, time anong al sais in he olan. 1 poste dat the ie blog soon Wi yield a vale of Max77, tat isles than the arable tl ine AT. This situton cccursin the folowing example Kj (sas) EXAMPLE SA.3. MinedModel Assembly Line Balancing ‘Thisis a coaticuaton of Example ISA.2. For the two models A and B, hourly production rates are 4 nits for A and 6 units for B, Most ofthe work ements are common to the two modes, but in some cases be elements take loager for one mode than forthe other. Te elements, ties, nd prosedence Fequrements are given in Table 15A.1. Also given: E = O5€, repositioning ‘TABLE 164.1 Work Elements for Models And 8 in Example 1682 Work Elemertk —Tearimia) ——Precededby —_Tegclmin) __Procaded by a oe aaa a 8 &(Chap 16 / Manual Aeeemby Lines time 7, = 0.15 min, art = 1 for all (a) Construct the precedence ci. ram foreach model and fr both models combined ino one dagram.() Use ‘he Kilvidge and Wester method (0 sole the line balancing problem, () Determine she balance effiency or the solution in) Solution: (a) Tue precedence diagrams are shown in Figure 158. (0) Touse the Kileidge and Wester method (calculate total production tne requirements for each work clement, TZ, according to Equation (154.11 this is done in Table 15A.2; 2 aang the elements according to columns in the preoodenc diagram, asin Table 15A.3 (within columss, the elements ae Figure LSA.1_ Precedence diazams for Example 15A.3:(aformode A (for mode B, and (9 forboth models combined. TABLE 16A2 Tota Times Requied for Each Element in Each Modelo Mest Respective Production ates and for Both Modals in Example 154.3 mem —Aeteu tin) atin) Fen vin 7 @ @ w 2 6 2m a 3 : ® 2 4 4 2 eu 5 2 0 @ 6 6 2 2 7 ° a u a Fy au a 258 ‘Appendix TSA | BatchModl and Mixedodel Lines 43 TABLE 1643. Elements Arangedin Colum in Example 164.3 Boment “receded by 7 4 1 2 1 3 1 8 3 7 © % 4 5 w 2 2 a v 4 567 lise acorn tote Ingest canine rule} and (3) soe elements vwerlsaons by king tbe teste proceeded in Seton 193 To Accomplish his hid step he eae tne pr workers computa Froporion uptime E = 086 and sepostoning tency E, To dstemineE tot tithe al produon ate = 4+ 6» 1a Thecrspon ing tine oun by malin the resrocl of ht by poporion vptine and acount for he eres in tei flows (086) 1 Te servo tne each lest eli she epson tine T T= 515~ 01 Now potting ice an be dtenind allows B= S6i85%6 = 0904 576 min 61 min enc, available time agaist which the fn i tobe balanced is AT = 60(096)(0974) = $6..mia Allocating clement to tations agains this imi, the final solution is presented inTable 5A TABLE 16A4 locaton ot Wok Elements to Statons in Example 1543 by Using the Kabidge and Wester Method Suton Element ——Thxin) _—_TTamin) TO 3 26 38 2 4 5 ET a 2 “ 5 w 4 6 ca 7 24 8 5 8 “% ry(Caap. 15 / Manual Asimbly Lines (6) Balance efficiency is determined by Equation (I5A.13). Mox( 77, ‘5 min. Note that hs aig les than the avalale tie of 56.1 mins the line wll operate slightly faster than orginal >¥ wrod, 238 sy = FE = asnt = 921% Pa mee ‘Model Launching in Mixed Model Lines, It was previously note that produc. ‘ion om manual assembly ine eypclly involves launching of base parts ont the be ing ofthe line at regula ine intervals na single-mode! line hist itera is constant and sol equal tothe eel time JThe same applies fora betch-model ine, bat Tislkely to cities foreach batch because the models ae diferent and ther production equicements ace probably diferent In a mixed-mode ine, mode! launching is more complicated because each models likely to havea diferen work coment time, which trauslates into diferent station service times, Thus the time interval between launches and te selection of which modelo launch ace interdependent. For example, ia series ‘of models with igh work coatent mes ar launched at short time intervals the asses ‘by fne wil quickly becom congested (overwhelmed by too much work). On the other hand, ia series of models with low work content ies are launched at long tne inter vals, then stators wl be starved for work (with resulting idleness), Neither congestion nor idleness desrale Determining the time interval between succesivelauacbes i referred to asthe lacing displ. Two eteratve launching disciplines are avaiable for mixed-mode! assembly ins (1) vasiable-ate launching and (2) fixed-rate laching. Variable Rate Launching. In variablerate launching, the time interval between the launching ofthe cucont hase part and the next eset equal to tke eyle time ofthe cartent unit Sinve different models bave efferent work conten! times and thus diferest task times per station, thee cel ines and lunchtime interval vary. The tim interval in variable rate launching cen be expresed as Te (5A19) Tali) WEE, where Ty{j) = time interval before the next Lunch in vatiblete launching, mins Tag = work content time of the product just launched (model), min; w = mamber of workers on the line E, = repostoning efficiency and Ej = balance eliciency. If man ning level MG = 1 fr ali then the numberof stations canbe substituted forw. With ‘ariableate launching, a long asthe launching intervals determined by this formula, ‘en models an be laueched in any sequence desired. PXAMPLE ISA Variable-Rate Lauaching ina Mixed Model Assembly Line Determine the variebleate launching intervals for models snd B ia Examples 15A.2 and ISAS. From the resus of Example 1583, £, = 0574 Append 1 / Boch Mede and itxed: Mode! Lines 35 Solmion:Ajyng Eton 54.4) formal A na Tals 5(974)( 921) = 6.020 in And for model, When s unit of mode A is launched onto the font ofthe ine, 620 min must else ‘before the next launch. When a unit of model B is launched onto the font ofthe line, 5.74 min mus elapse before the next faunch, The advantage of vaiable-rate Launching is that units canbe launched in any ‘otder without causing ile time or congestion a workstations, as log a the specified ‘model micis achieved by tbe end of the shift. The model mix canbe adjusted ata mo- ‘ments notice to adapt to changes in demand forte various products made on te line However, certain tecnical aad logistical issues mast be advessed when variable rate launching i used. One technical issue thatthe work carriers on @ moving conveyor ae usually located at constant intervals along its length ad so the work units must be attached ony at these postions. This isnot compatible with variablerate launching ‘hic presumes that work nits canbe attached at any location slog the conveyor cor- responding othe variable rate lavochng interval 7, forthe preceding model. One of the logistical issues in varieble-rat launching i the problem of supplying the correct components and subassemblies to the individual stations forthe models being essem- ‘ed on the tine at any given moment. Because ofthese kinds of sues, industry sms to prfer fied-rateieuaching. Fixed-Rate Launching for Two Models. In fixed-rate zunchng, the tme interval between two conserve launches is constant. This launching discipline is ull et by the speed of the conveyor and te spacing between work carers (eg, Rooks cn a cain conveyor era at regular spacing inthe chs). The time interval ed rte iaunching pend on the product mix and production rates of models on the ine, OF eure, the Schedule must be consistent with the tne and manpower availabe on the He, so epod- tioning efcieny and ine balance efceney must be figured in Given the houlyproduc- tion schedule, a wellas values of and Ft launching tine intervals determined 4g RA 19 (5A5) ‘where T= tne interval betwen launches in ned-at launching min: = production sate of model, nite; Tay = work content time of model jaf, = total pro-

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