06 Balanceo de Líneas y Layout II

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Layout strategies and

line balancing II
Juan Felipe Reyes Rodríguez
Types of layout
1. Office layout
2. Retail layout
3. Warehouse layout
4. Fixed-position layout
5. Work-cell layout
6. Product-oriented layout
7. Process-oriented layout
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6. Repetitive/product-oriented layout
Organized around products or families of similar high-volume,

low-variety products
Volume is adequate Supplies of raw materials
for high equipment and components are
utilisation adequate and of uniform
quality
Product demand is Product is standardized

stable enough to or approaching a phase
justify high of life cycle that
investment in justifies investment
specialized equipment
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Advantages
• Low variable cost
per unit
• Low material
handling costs
Disadvantages • Reduced work-in-
process inventories
• High volume is
• Easier training and
required
supervision
• Work stoppage at
any point ties up the • Rapid throughput
whole operation
• Lack of flexibility in
product or
production rates
MacDonald’s assembly line
Source: Heizer, J., & Render, B. (2014). Operations management: Sustainability and Supply Chain Management
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Disassembly lines
• Disassembly is being considered in new product

designs
• “Green” issues and recycling standards are important
consideration
• Automotive disassembly
is the 16tthlargest
industry in
the US
Assembly line balancing
• Objective is to minimize the imbalance

between machines or personnel while
meeting required output
• Starts with the precedence
relationships
1. Determine cycle time
2. Calculate theoretical
minimum number of
workstations
3. Balance the line by
assigning specific tasks
to workstations
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• Minimizes the idle time along the line

and results in a high utilization of labour
and equipment.
• Contributes to smooth flow of work as

activities along the line are
synchronised.
• Prevents morale problems at the slower

stations for workers who must work
continuously.
Sequence of operations at an automatic carwash
Scrubbing Rinsing Drying

2 min 4 min 2 min
Ideal combination of scrubbing and drying into one

workstation: 4 min
It’s not possible due to the sequence of operations
One basic assumption: There is one worker per workstation
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Assembly line balancing:
Cycle time
The maximum time allowed

at each workstation to
complete its set of tasks on a
unit. The time that takes one
unit to leave the process
after the previous one
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Assembly line balancing: Example
10 min 20 min 15 min 25 min 30 min
Operation 1 Operation 2 Operation 3 Operation 4 Operation 5
Minimum cycle time: Longest task time – Each 30 minutes a unit leaves
the process
Applies if there were five workstations
Maximum cycle time: Sum of the task times – Each 100 min a unit leaves
the process
Applies if all tasks were performed at a single workstation
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Output rate: Number of units that can be produced per day
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟 𝑑𝑎𝑦
𝑂𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑒 =
𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒
Assume that the line operates eight hours per day (480 minutes). With the minimum cycle
time of 30 min, the output rate is
480 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦
𝑂𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑒 = = 16 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦
30 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝑝𝑒𝑟 𝑏𝑎𝑡𝑐ℎ
With the maximum cycle time of 100 min, the output rate is

𝑂𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑒 = = 4,8 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦
A desirable output must be then between 4,8 and 16 batches per day
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Output rate: Number of units that can be produced per day
𝑂𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑒 =
With a desired output rate then

𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 =
𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑜𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑒
If 16 batches are desired the necessary cycle time is
𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 = = 30 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝑝𝑒𝑟 𝑏𝑎𝑡𝑐ℎ
16 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦
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Assembly line balancing: Number of
Workstations
Number of workstations depends on the desired
output rate.
A theoretical minimum number of workstations

can be determined
∑𝑡
𝑁𝑚𝑖𝑛 =
𝑁𝑚𝑖𝑛 = 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠
@ 𝑡 = 𝑆𝑢𝑚 𝑜𝑓 𝑡𝑎𝑠𝑘 𝑡𝑖𝑚𝑒𝑠
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Assembly line balancing: Number of Workstations - Example

Assume the desired output is the maximum of 16 batch per day. It means a cycle
time of 30 minutes. The minimum number of workstations is:
∑𝑡
𝑁𝑚𝑖𝑛 =
𝑁𝑚𝑖𝑛 = = 3.33 ≈ 4 𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠
30 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑝𝑒𝑟 𝑠𝑡𝑎𝑡𝑖𝑜𝑛
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Assembly line balancing: Precedence diagrams
A diagram that shows elemental tasks and their precedence requirements.
The diagram is read from left to right, so the initial task(s) are on the left and
the final task is on the right.
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Assembly line balancing: Heuristics and rules
Line balancing is based mostly on heuristic (intuitive) rules.
Rule Explanation
Longest task time Choose the available task with the longest task time
Most following tasks Choose the available task with the largest number of
following tasks
Ranked positional weight Choose the available task for which the sum of
following task times is the longest
Shortest task time Choose the available task with the shortest task time
Least number of following Choose the available task with the least number of
tasks following tasks
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Assembly line balancing: Idle time and efficiency
Idle time is referred as balance delay
𝐼𝑑𝑙𝑒 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟 𝑐𝑦𝑐𝑙𝑒

𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝑖𝑑𝑙𝑒 𝑡𝑖𝑚𝑒 = ∗ 100%
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ∗ 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒
Nactual=Actual number of stations
Efficiency of the line

𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 100% − 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝑖𝑑𝑙𝑒 𝑡𝑖𝑚𝑒
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Assembly line balancing: Summary
Distribute tasks among
Calculate number of workstations based on
workstations heuristics
Illustrate grouped tasks
∑𝑡
𝑁𝑚𝑖𝑛 = in precedence diagram
04 06
03 05
Calculate percentage of
Calculate cycle time. idle time and efficiency
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𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟 𝑑𝑎𝑦 𝐼𝑑𝑙𝑒 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟 𝑐𝑦𝑐𝑙𝑒
𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 = 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑖𝑑𝑙𝑒 𝑡𝑖𝑚𝑒 = ∗ 100%
𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑜𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑒 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ∗ 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒
Elaborate precedence
01 diagram if necessary.
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0.1 min 1.0 min
a b
0.7 min 0.5 min 0.2 min
c d e
Tiempo de ciclo= 1.0 min
Tiempo operación diario= 480 minutos diarios(8 horas)
𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑜𝑝𝑒𝑟𝑎𝑐𝑖ó𝑛 𝑑𝑖𝑎𝑟𝑖𝑜
𝑂𝑢𝑡𝑝𝑢𝑡 𝑟𝑎𝑡𝑒(𝑡𝑎𝑠𝑎 𝑑𝑒 𝑠𝑎𝑙𝑖𝑑𝑎) =
𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑐𝑖𝑐𝑙𝑜
480 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑑í𝑎
𝑇𝑎𝑠𝑎 𝑑𝑒 𝑠𝑎𝑙𝑖𝑑𝑎 = = 480 𝑢𝑛𝑖𝑑𝑎𝑑𝑒𝑠 𝑝𝑜𝑟 𝑑í𝑎
1.0 𝑚𝑖𝑛𝑢𝑡𝑜 𝑝𝑜𝑟 𝑢𝑛𝑖𝑑𝑎𝑑
21
Calculate number of
workstations
∑𝑡
𝑁𝑚𝑖𝑛 =
03
Calculate cycle time.

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22
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0.1 min 1.0 min
a b
0.7 min 0.5 min 0.2 min
c d e
0.1 + 1.0 + 0.7 + 0.5 + 0.2 = 2.5 min
∑𝑡
𝑁ú𝑚𝑒𝑟𝑜 𝑚𝑖𝑛𝑖𝑚𝑜 𝑑𝑒 𝑒𝑠𝑡𝑎𝑐𝑖𝑜𝑛𝑒𝑠 𝑑𝑒 𝑡𝑟𝑎𝑏𝑎𝑗𝑜 (𝑁𝑚𝑖𝑛) =
2,5 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑢𝑛𝑖𝑑𝑎𝑑
𝑁𝑚𝑖𝑛 = = 2,5 ≈ 3 𝑒𝑠𝑡𝑎𝑐𝑖𝑜𝑛𝑒𝑠
1.0 𝑚𝑖𝑛𝑢𝑡𝑜 𝑝𝑜𝑟 𝑢𝑛𝑖𝑑𝑎𝑑 𝑝𝑜𝑟 𝑒𝑠𝑡𝑎𝑐𝑖ó𝑛
SIEMPRE se redondea al entero superior
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∑𝑡
𝑁𝑚𝑖𝑛 =
04
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Tiempo Tiempo muerto de

Estación de Tarea Duración de Tiempo restante
restante Elegible la estación de
trabajo asign tarea (min) revisado(min)
(min) trabajo (min)
1 1,0 a,c a 0,1 0,9
0,9 b,c c 0,7 0,2
0,2 Ninguna 0,2
2 1,0 b b 1,0 0,0 0,0
3 1,0 d d 0,5 0,5
0,5 e e 0,2 0,3
0,3 Ninguna 0,3
Total tiempo
muerto (idle time) 0,5
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∑𝑡
04
03 05

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Tiempo muerto de la
Estación de Tiempo Tarea Duración de Tiempo restante
Elegible estación de trabajo
trabajo restante (min) asign tarea (min) revisado(min)
(min)
1 1,0 a,c a 0,1 0,9
0,9 b,c c 0,7 0,2
0,2 Ninguna 0,2
2 1,0 b b 1,0 0,0 0,0
3 1,0 d d 0,5 0,5
0,5 e e 0,2 0,3
0,3 Ninguna 0,3
Total tiempo muerto
(idle time) 0,5
0.1 min 1.0 min

Estación 2
a b
Estación 3
Estación 1 0.7 min 0.5 min 0.2 min
c d e
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∑𝑡
04 06
03 05
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Assembly line balancing: Idle time and efficiency
𝑇𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜

𝑃𝑜𝑟𝑐𝑒𝑛𝑡𝑎𝑗𝑒 𝑑𝑒 𝑡𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜 = ∗ 100%
𝑁𝑟𝑒𝑎𝑙 ∗ 𝑡𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑐𝑖𝑐𝑙𝑜
0,5 𝑚𝑖𝑛
𝑃𝑜𝑟𝑐𝑒𝑛𝑡𝑎𝑗𝑒 𝑑𝑒 𝑡𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜 = ∗ 100% = 16,7%
3 ∗ 1,0 𝑚𝑖𝑛
𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 𝑝𝑜𝑟𝑐𝑒𝑛𝑡𝑎𝑗𝑒 𝑑𝑒 𝑡𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜
𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 16,7% = 83,3%
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∑𝑡
04 06
03 05
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30
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Assembly line balancing: Example 2
Tarea Predecesor Tiempo de Asuma un día de trabajo de ocho horas
inmediato tarea (min) y calcule el tiempo de ciclo requerido
para obtener una producción de 400
a - 0,2 unidades al día.
b a 0,2 Calcule el porcentaje de tiempo

c - 0,8 muerto y de eficiencia del sistema.
d c 0,6 Reglas heurísticas de asignación
e b 0,3 1. Mayor número de tareas
dependientes
f d, e 1,0
2. Tarea más larga
g f 0,4
h g 0,3
St=3,8
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0.2 min 0.2 min 0.3 min
a b e
0.8 min 0.6 min 1.0 min 0.4 min 0.3 min
c d f g h
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Asuma un día de trabajo de ocho horas y calcule el tiempo de ciclo

requerido para obtener una producción de 400 unidades al día.
𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑜𝑝𝑒𝑟𝑎𝑐𝑖ó𝑛
𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑐𝑖𝑐𝑙𝑜 =
𝑆𝑎𝑙𝑖𝑑𝑎 𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑐𝑖ó𝑛 𝑑𝑒𝑠𝑒𝑎𝑑𝑎

𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑐𝑖𝑐𝑙𝑜 = = 1,2 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜
400 𝑢𝑛𝑖𝑑𝑎𝑑𝑒𝑠 𝑝𝑜𝑟 𝑑í𝑎
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Calculate number of
workstations
∑𝑡
𝑁𝑚𝑖𝑛 =
03

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36
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∑𝑡
𝑁𝑚𝑖𝑛 =
𝑁𝑚𝑖𝑛 = = 3,17 ≈ 4 𝑒𝑠𝑡𝑎𝑐𝑖𝑜𝑛𝑒𝑠 𝑑𝑒 𝑡𝑟𝑎𝑏𝑎𝑗𝑜
1,2 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜
37
∑𝑡
𝑁𝑚𝑖𝑛 =
04
03

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Estación de Tiempo restante Duración de
Elegible Tarea asignar restante la estación de
trabajo (min) tarea (min)
revisado(min) trabajo (min)
1 1,2 a,c a 0,2 1,0
1,0 b,c c 0,8 0,2
0,2 b,d b 0,2 0,0
0,0 d,e Ninguna 0,0
2 1,2 d,e d 0,6 0,6
0,6 e e 0,3 0,3
0,3 f Ninguna 0,3
3 1,2 f f 1,0 0,2
0,2 g Ninguna 0,2
4 1,2 g g 0,4 0,8
0,8 h h 0,3 0,5
0,5 Ninguna Ninguna 0,5
Total tiempo
Reglas heurísticas de asignación muerto 1,0
1. Mayor número de tareas dependientes
2. Tarea más larga
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∑𝑡
04
03 05

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40
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Workstation 2
0.2 min 0.2 min 0.3 min
a b e
Workstation 4
c d f g h
Workstation 1 Workstation 3
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∑𝑡
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03 05
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42
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1,0 𝑚𝑖𝑛
4 ∗ 1,2 𝑚𝑖𝑛
𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 20,83% = 79,17%
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Tarea Predecesor Tiempo de Asuma un día de trabajo de ocho horas
inmediato tarea (min) y calcule el tiempo de ciclo requerido
para obtener una producción de 400
a - 0,2 unidades al día.
b a 0,2 Calcule el porcentaje de tiempo

c - 0,8 muerto y de eficiencia del sistema.
d c 0,6 Reglas heurísticas de asignación
e b 0,3 1. Mayor número de tareas
dependientes
f d, e 1,0
2. Tarea más larga
g f 0,4
h g 0,3
St=3,8
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2.4 min 2.2 min 2.0 min
0.2 min 0.2 min 0.3 min
a b e
1.7 min 0.7 min 0.3 min
3.1 min 2.3 min
c d f g h
Peso posicional de a = 0,2 + 0,2 + 0,3 + 1,0 + 0,4 + 0,3 = 2,4 à Se suman los
tiempos de la actividad y los de las actividades dependientes
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Asuma un día de trabajo de ocho horas y calcule el tiempo de ciclo

requerido para obtener una producción de 400 unidades al día.
𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑜𝑝𝑒𝑟𝑎𝑐𝑖ó𝑛
𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑐𝑖𝑐𝑙𝑜 =
𝑆𝑎𝑙𝑖𝑑𝑎 𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑐𝑖ó𝑛 𝑑𝑒𝑠𝑒𝑎𝑑𝑎

𝑇𝑖𝑒𝑚𝑝𝑜 𝑑𝑒 𝑐𝑖𝑐𝑙𝑜 = = 1,2 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜
400 𝑢𝑛𝑖𝑑𝑎𝑑𝑒𝑠 𝑝𝑜𝑟 𝑑í𝑎
48
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Calculate number of
workstations
∑𝑡
𝑁𝑚𝑖𝑛 =
03

02
22/02/21 49
49
∑𝑡
𝑁𝑚𝑖𝑛 =
𝑁𝑚𝑖𝑛 = = 3,17 ≈ 4 𝑒𝑠𝑡𝑎𝑐𝑖𝑜𝑛𝑒𝑠 𝑑𝑒 𝑡𝑟𝑎𝑏𝑎𝑗𝑜
1,2 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜
50
25
22/2/21
∑𝑡
𝑁𝑚𝑖𝑛 =
04
03

02
22/02/21 51
51
Estación de Tiempo restante Duración de
Elegible Tarea asignar restante la estación de
trabajo (min) tarea (min)
revisado(min) trabajo (min)
1 1,2 a,c c 0,8 0,4
0,4 a,d a 0,2 0,2
0,2 b,d b 0,2 0,0
0,0 d,e Ninguna 0,0
2 1,2 d,e d 0,6 0,6
0,6 e e 0,3 0,3
0,3 f Ninguna 0,3
3 1,2 f f 1,0 0,2
0,2 g Ninguna 0,2
4 1,2 g g 0,4 0,8
0,8 h h 0,3 0,5
0,5 Ninguna Ninguna 0,5
Total tiempo
Reglas heurísticas de asignación muerto 1,0
1. Mayor número de tareas dependientes
2. Tarea más larga
52
26
22/2/21
∑𝑡
04
03 05

02
22/02/21 53
53
Workstation 2
0.2 min 0.2 min 0.3 min
a b e
Workstation 4
c d f g h
Workstation 1 Workstation 3
54
27
22/2/21
∑𝑡
04 06
03 05
02
22/02/21 55
55

1,0 𝑚𝑖𝑛
4 ∗ 1,2 𝑚𝑖𝑛
𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 20,83% = 79,17%
56
28
22/2/21
Bottleneck
An operation in a sequence of operations
whose capacity is lower tan that of the
other operations
It causes a drop of efficiency
It determines the speed of a process and
the total capacity of the process
Normally it has high accumulated
inventory to process (queue)
57
Bottleneck
58
29
22/2/21
Bottleneck
The bottleneck is the activity with the longest time.
There are five operations with the following times

What is the bottleneck?
59
Bottleneck

𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠
6 3 4 2,4 2
ℎ ℎ ℎ ℎ ℎ
60
30
22/2/21
Bottleneck

𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠 𝑢𝑛𝑖𝑡𝑠
6 3 4 2,4 2
ℎ ℎ ℎ ℎ ℎ
Bottleneck
Cycle time of the system = 30 min (every 30 minutes a unit leaves the system)
61
Bottleneck
30 min
There are five operations with the following times Operation 5
10 min 20 min 15 min 25 min

Operation 1 Operation 2 Operation 3 Operation 4
30 min
Operation 5
Cycle time operation 5 = 30 minutes/2 workers = 15 minutes
New Bottleneck
New cycle time of the system = 25 minutes
62
31
22/2/21
Other approaches for balancing
• Line designed to handle more

than one product on the same
line.
A Dynamic line
balancing
• The products have to be fairly
similar, so that the tasks involved
are pretty much the same for all
products
• Cross-train workers to
perform more than one
task.
• When bottlenecks occur,
the workers with
Mixed model line
B
temporarily increased idle
time can assist other
workers who are
temporarily overburdened.
63
Ejercicio 6
Questions | Discussion
64
32
22/2/21
Thank
you!
Contact: juanf.reyes@upb.edu.co
https://www.linkedin.com/in/juanfelipereyes/
65
33

06 Balanceo de Líneas y Layout II

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06 Balanceo de Líneas y Layout II

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Layout strategies and

Organized around products or families of similar high-volume,

Product demand is Product is standardized

• Disassembly is being considered in new product

• Objective is to minimize the imbalance

• Minimizes the idle time along the line

• Contributes to smooth flow of work as

• Prevents morale problems at the slower

Sequence of operations at an automatic carwash

Scrubbing Rinsing Drying

Ideal combination of scrubbing and drying into one

It’s not possible due to the sequence of operations

One basic assumption: There is one worker per workstation

The maximum time allowed

Operation 1 Operation 2 Operation 3 Operation 4 Operation 5

10 min 20 min 15 min 25 min 30 min

Operation 1 Operation 2 Operation 3 Operation 4 Operation 5

480 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦

𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟 𝑑𝑎𝑦

A theoretical minimum number of workstations

@ 𝑡 = 𝑆𝑢𝑚 𝑜𝑓 𝑡𝑎𝑠𝑘 𝑡𝑖𝑚𝑒𝑠

10 min 20 min 15 min 25 min 30 min

A diagram that shows elemental tasks and their precedence requirements.

Idle time is referred as balance delay

𝐼𝑑𝑙𝑒 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟 𝑐𝑦𝑐𝑙𝑒

Efficiency of the line

Calculate cycle time.

Calculate cycle time.

Tiempo Tiempo muerto de

Calculate cycle time.

0.1 min 1.0 min

Estación 1 0.7 min 0.5 min 0.2 min

𝑇𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜

𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 𝑝𝑜𝑟𝑐𝑒𝑛𝑡𝑎𝑗𝑒 𝑑𝑒 𝑡𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜

𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 16,7% = 83,3%

b a 0,2 Calcule el porcentaje de tiempo

0.2 min 0.2 min 0.3 min

Calculate cycle time.

Asuma un día de trabajo de ocho horas y calcule el tiempo de ciclo

480 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑑í𝑎

Calculate cycle time.

Calculate cycle time.

Calculate cycle time.

𝑇𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜

𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 𝑝𝑜𝑟𝑐𝑒𝑛𝑡𝑎𝑗𝑒 𝑑𝑒 𝑡𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜

𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 20,83% = 79,17%

b a 0,2 Calcule el porcentaje de tiempo

Calculate cycle time.

Asuma un día de trabajo de ocho horas y calcule el tiempo de ciclo

480 𝑚𝑖𝑛𝑢𝑡𝑜𝑠 𝑝𝑜𝑟 𝑑í𝑎

Calculate cycle time.

Calculate cycle time.

Calculate cycle time.

𝑇𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜 𝑝𝑜𝑟 𝑐𝑖𝑐𝑙𝑜

𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 𝑝𝑜𝑟𝑐𝑒𝑛𝑡𝑎𝑗𝑒 𝑑𝑒 𝑡𝑖𝑒𝑚𝑝𝑜 𝑚𝑢𝑒𝑟𝑡𝑜

𝐸𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑖𝑎 = 100% − 20,83% = 79,17%

There are five operations with the following times

10 min 20 min 15 min 25 min 30 min

What is the bottleneck?

There are five operations with the following times

10 min 20 min 15 min 25 min 30 min