Assembly Line Balancing

Introduction to Industrial
Engineering
The Line Balancing Problem
The problem is to arrange the individual
processing and assembly tasks at the
workstations so that the total time
required at each workstation is
approximately the same.
Nearly impossible to reach perfect
balance
Things to consider
Sequence of tasks is restricted, there is
a required order
Called precedence constraints
There is a production rate needed, i.e.
how many products needed per time
period
Design the line to meet demand and
within constraints
Terminology and Definitions
Minimum Work Element
Total Work Content

Workstation Process time

Cycle Time

Precedence Constraints

Balance Delay
Minimum Work Element

Dividing the job into tasks of a

rational and smallest size
Example: Drill a hole, cant be
divided
Symbol Time for element j: Tej
is a constant

Tej
Total Work Content
Aggregate of work
elements

n
Twc Tej
j 1
Workstation Process time

The amount of time for an individual

workstation, after individual tasks have
been combined into stations
Sum of task times = sum of workstation
times
Cycle time
Time between parts coming off the line
Ideally, the production rate, but may
need to be adjusted for efficiency and
down time
Established by the bottleneck station,
that is station with largest time
Precedence Constraints
Generally given, determined by the
required order of operations
Draw in a network style for
understanding
Cannot violate these, an element must
be complete before the next one is
started
Balance Delay
Measure of line
inefficiency due to
imbalances in
station times nTc Twc
d
nTc
Method Largest Candidate Rule
Listelements in descending order of T
Assign elements to first station, from top
to bottom of list, minding constraints, and
not causing sum to exceed cycle time
Continue assigning elements to stations
where each station < cycle time, largest
assigned first, until all assigned
EXAMPLE