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2 Twc
Total work
content
Twc = Tej
j 1
A. BACKLASH ASSEMBLY
MOUNT TRANS.CASE,
COUNTER SHAFT, BULL CAGE
1 4.89
LH AND RH AND
Work DIFFERENTIAL CASE
n n
station
3 Tsi
process Tsi = Tej 2 NUMBER PUNCHING 0.14
j 1 j 1 3 BRING SPLINE SHAFT 0.17
time 4 COLLECT MATERIAL 0.40
Cycle 5 PUSH SKID TO NEXT STAGE 0.26
4 Tc ---
Time 6 PRELOAD LH 5.79
Balance d = (nxTc – Twc) / 7 MOUNT SPLINE SHAFT 1.61
5 d
Delay (nxTc)
8 CHECK BACKLASH 0.42
Line
6 E E = (Twc) / (nxTc) 9 BACKLASH LH 2.78
Efficiency
10 COLLECT MATERIAL 0.40
B) PRECEDENCE DIAGRAM Fig. (1): 11 PUSH SKID TO NEXT STAGE 0.26
12 BACKLASH RH 2.78
Refer page no. 5 13 BACKLASH RECHECK 0.42
14 COLLECT MATERIAL 0.40
15 FINAL LH BULLCAGE TIGHT 1.99
16 FINAL RH BULLCAGE TIGHT 1.99
C) CYCLE TIME BY ‘MOST’ METHOD: MTG. C’SHAFT FRT BEARING
17 1.32
Following are the elemental cycle times for each COVER
MTG. DRIVE SHAFT (WITHOUT
and every activity of transmission line. These cycle 18
TORQUE)
1.04
times are taken by Maynard Operation Sequence 19 TORQUE DRIVE SHAFT 0.30
Technique (MOST). 20 AXLE BOLT PLACING 1.40
B. CLUTCH HOUSING
Sub Assembly Stations (Table No. 2): MOUNT CLUTCH HOUSING FIR
1 C’HSG. GASKET, DOWEL AND 6.84
G.NIPPLE.
TIME C. REAR AXLE MOUNTING
S.N. ACTIVITY
(MIN.) 1 MOUNT LH BRAKE 1.13
1 COUNTER SHAFT SUB ASSLY. 5.37 2 MOUNT LH BULL GEAR 0.64
2 BULL SHAFT SUB ASSLY. 4.48 3 LOAD LH AXLE 2.59
3 DRIVE SHAFT SUB ASSLY. 1.55 4 AXLE BOLT PLACING 1.4
4 DIFF CASE SHAFT SUB ASSLY. 11.66 5 TIGHT LH AXLE 1.00
5 SPLINE SHAFT SUB ASSLY. 14.28 6 BOLT PLACING 0.76
REAR AXLE CARRIER SUB 7 PRESS BOLT 1.13
6 9.04
ASSLY. 8 MOUNT RH BRAKE 1.13
7 GEAR SHIFTER SUB ASSLY. 11.06 9 MOUNT RH BULL GEAR 0.64
8 CLUTCH HOUSING SUB ASSLY. 7.17 10 LOAD RH AXLE 2.59
11 AXLE BOLT PLACING 1.4
12 TIGHT RH AXLE 1.00
D) ASSUMPTIONS: 13 BOLT PLACING 0.76
14 PRESS BOLT 1.13
D. BRAKE AND PTO MOUNTING
1.Production schedule is 3500 transmissions 1 BRAKE & AXLE TORQUE 1.19
per month. Assume 25 working days. So, 2 BRAKE & AXLE TORQUE 1.19
we require 140 transmissions / day i.e. 70 3 PTO FITTING 2.60
Tr. / shift if we run two shifts. G.S. MOUNTING &
E
TRANSMISSION TESTING
2. Shift timings: Shift I & II: 420 min. each. MOUNT GEAR SHIFTER SUB
3. Time Available to Complete the Task 1 3.32
ASSEMBLY
(TACT) = 420 / 70 = 6 Min. 2
MOUNT TRANSMISSION CASE
2.00
Cycle times of all operations are known. ON SKID
3 FILL OIL & TESTING 17.5
IA 349
Application of Ranked Positional Weight Method for Assembly Line Balancing – A Case Study
TRANSMISSION ASSEMBLY LINE TIME
TN. ACTIVITY DESCRIPTION
(MIN.)
(Table No. 4):
11A & B
TIME MOUNT CLUTCH HSG. FIR
STN. ACTIVITY DESCRIPTION C’HSG. GASKET, DOWEL 6.84
(MIN.)
AND G.NIPPLE.
COUNTER SHAFT SUB
1 5.37 MOUNT LH BRAKE 1.13
ASSLY.
MOUNT LH BULL GEAR 0.64
BULL CAGE LH-RH SUB
2 4.84 LOAD LH AXLE 2.59
ASSLY.
DIFF. CASE SUB ASSLY. COLLECT MATERIAL 0.40
3A & B 11.66 PUSH SKID TO NEXT STAGE 0.26
(2 PARALLEL STATIONS)
DRIVE SHAFT SUB ASSLY . (2 PARALLEL STATIONS) 11.86
4 A, B 1.55 12
SPLINE SHAFT SUB ASSLY.
&C 14.28 AXLE BOLT PLACING 1.4
(3 PARALLEL STATIONS)
15.83 TIGHT LH AXLE 1.00
RAC SUB ASSLY. BOLT PLACING 0.76
5 A, B 9.04 PRESS BOLT 1.13
CLUTCH HSG. SUB ASSLY.
&C 7.17 COLLECT MATERIAL 0.40
(3 PARALLEL STATIONS)
16.21 PUSH SKID TO NEXT STAGE 0.26
GEAR SHIFTER SUB ASSLY. 4.94
6A & B 11.06 13
(2 PARALLEL STATIONS)
7 MOUNT RH BRAKE 1.13
MOUNT TRANS.CASE, MOUNT RH BULL GEAR 0.64
COUNTER SHAFT, BULL LOAD RH AXLE 2.59
4.89
CAGE LH AND RH AND COLLECT MATERIAL 0.40
DIFFERENTIAL CASE PUSH SKID TO NEXT STAGE 0.26
NUMBER PUNCHING 0.14 5.02
BRING SPLINE SHAFT 0.17 14
COLLECT MATERIAL 0.40 AXLE BOLT PLACING 1.4
PUSH SKID TO NEXT STAGE 0.26 TIGHT RH AXLE 1.00
5.86 BOLT PLACING 0.76
8A & B PRESS BOLT 1.13
PRELOAD LH 5.79 COLLECT MATERIAL 0.40
MOUNT SPLINE SHAFT 1.61 PUSH SKID TO NEXT STAGE 0.26
CHECK BACKLASH 0.42 4.94
BACKLASH LH 2.78 15
COLLECT MATERIAL 0.40 BRAKE & AXLE TORQUE 1.19
PUSH SKID TO NEXT STAGE 0.26 BRAKE & AXLE TORQUE 1.19
(2 PARALLEL STATIONS) 11.26 PTO FITTING 2.60
9 COLLECT MATERIAL 0.40
BACKLASH RH 2.78 PUSH SKID TO NEXT STAGE 0.26
BACKLASH RECHECK 0.42 5.63
FINAL LH BULL CAGE TIGHT 1.99 16
COLLECT MATERIAL 0.40 MOUNT GEAR SHIFTER SUB
3.32
PUSH SKID TO NEXT STAGE 0.26 ASSEMBLY
5.85 MOUNT TRANSMISSION
2.00
10 CASE ON SKID
FINAL RH BULL CAGE TIGHT 1.99 5.32
MTG. C’SHAFT FRT BEARING 17
1.32
COVER A, B & C
MTG. DRIVE SHAFT 1.04 FILL OIL & TESTING 17.50
TORQUE DRIVE SHAFT 0.30 (3 PARALLEL STATIONS) 17.50
5.32 TOTAL 92.52
STN: Station
E) APPLICATION OF LINE BALANCING
METHOD
Helgeson and Birnie developed the ranked
positional weight method in 1961 [4]. It
combines the strategies of the largest candidate
rule & kilbridge and western method. A RPW is
computed for each element.
ICANDIA 2007 MED, COE, Pune, India
350 IA
Application of Ranked Positional Weight Method for Assembly Line Balancing – A Case Study
The RPW value takes account of the ‘Te’ value of
Element RPW Te Precedence
the element and its position in the precedence
diagram. Then the elements are assigned to work 16 11.15 5.32 15
station in the general order of their RPW values. 17 5.83 5.83 6 & 16
Steps: Step3 (Table No. 7):
1. Calculate RPW for each element by
summing the element together with the Station Element Te Station Element Te
‘Te’ values for the entire element that
follows it in the arrow chain of the 1 1 5.37 10 10 5.32
precedence diagram. 2 2 4.84 11 11 5.93
2. List the elements in the order of their
3 3 5.83 12 12 4.94
RPW, largest at the top of the list.
3. Assign elements to station according to 4 4 5.27 13 13 5.02
RPW, avoiding precedence constraint 5 5 5.4 14 14 4.94
and time cycle violations. 6 6 5.53 15 15 5.63
Step1 (Table No. 5): 7 7 5.86 16 16 5.32
Element RPW Element RPW 8 8 5.63 17 17 5.83
1 92.52 10 42.93 9 9 5.85
2 87.15 11 37.61
3 82.31 12 31.68 IV RESULT & CONCLUSION
4 76.48 13 26.74
5 71.21 14 21.72 Line Efficiency, E =
Twc =
92.52 X 100% = 91.77%
6 65.81 15 16.78 nTc 17 x5.93
7 60.28 16 11.15
nTc Twc 17 x5.93 92.52
8 54.42 17 5.83
Balance delay d = nTc = 17 x5.93 = 8.22 %
9 48.79
Smoothness Index = {(Idle time at Stn.1)2+(Idle time at
Step2 (Table No. 6): Stn.2)2+…...+(Idle time at Stn.17)2}1/2
= 2.47
Element RPW Te Precedence By applying line-balancing method we have increased
the production rate from 40 units to 70 units. The
1 92.52 5.37 ---
higher value of line efficiency & lower value of the
2 87.15 4.84 --- balance delay and smoothness index suggests that the
3 82.31 5.83 --- line is smooth [5].
4 76.48 5.27 ---
IV REFERENCES
5 71.21 5.4 ---
[1] Lee J. Krajewski and Larry P. Ritzman, "Operations
6 65.81 5.53 --- Management: Strategies and Analysis ", Ed. 5th, Addison-
7 60.28 5.86 1, 2 & 3 Wesley publishing Co. Inc., pp 425, 2000.
IA 351
Application of Ranked Positional Weight Method for Assembly Line Balancing – A Case Study
11A
8A
2
7 9 10 12 13 14 15 16 17
8B 7 7 7
11A
3A
3B
4A
5A
4B
5B
4C 6A
5C
6B
Station
1 2 3A 3B 4A 4B 4C 5A 5B 5C 6A 6B 7 8A 8B 9 10
No.
Time
5.37 4.84 11.66 15.83 16.21 11.06 5.86 11.26 5.85 5.32
(min.)
Station
11A 11B 12 13 14 15 16 17A 17B 17C
No.
Time
11.86 4.94 5.02 4.94 5.63 5.32 17.5
(min.)
352 IA