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CHAPTER 5

LINE BALANCING

5.1 INTRODUCTION
This is an analysis process which tries to equally divide work to be carried out in a
production process among workstations.
In production line workstations and work centers are arranged in a sequence of task to be
done along a straight or curved line.

5.2 GOAL OF PRODUCTION LINE ANAYSIS
Number of workstations needed.
Type of task should be assigned to each workstation.
To know the minimum number of workers, tools and machines that can be used to
provide the required amount of capacity.

5.3 OBJECTIVE OF LINEBALANCING
Assigning task to each workstation in such a way that there is only a little idle time.

5.4 TERMINOLOGIES RELATED TO PRODUCTION LINE ANALYSIS
TASKS: All the elements of work.


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TASK PRECEDENCE: The sequence in which tasks are performed.
TASK TIMES: Time required by a well-trained worker or unattended machine to
perform a task. This is usually expressed in minutes.
CYCLE TIME: The time expressed in minutes between two simultaneous products
coming off the end of a production line.
PRODUCTIVE TIME PER HOUR: The average number of minutes a workstation is
working in an hour.
WORKSTATION: A physical area where a worker with tools/ one or more machines, or
unattended machines like a robot performs a particular set of task in a production line.
WORK CENTER: A small group of identical workstations, where each workstation
performs the same set of task.
NUMBER OF WORKSTATIONS WORKING: The amount of work done at a work
center expressed in number of workstations.
MINIMUM NUMBER OF WORKSTATIONS: The least number of workstation that
provides the required production.
ACTUAL NUMBER OF WORKSTATIONS: This is the total number of workstations
required on the entire production line. It is calculated as the next higher integer of the
number of workstations working.
UTILIZATION: The percentage of time a production line is working.

5.5 LINE BALANCING PROCEDURE
1. Determination of tasks that must be performed to complete one unit of a product.
2. Determining the order or sequence of performing the whole set of tasks.


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3. Drawing precedence diagram. In this flowchart circles represents task and joining arrows
represents precedence.
4. Estimation of task time.
5. Calculation of cycle time.
6. Determination of minimum number of workstation required.
7. Using one of the heuristics to assign tasks to workstations for balancing production line.

5.6 METHOD OF LINE BALANCING
HEURISTIC: LARGE CANDIDATE RULE
KILBRIDEGE-WESTER HEURISTIC
HEURISTIC: HELGESON-BIRNIE

5.6.2 KILBRIDEGE-WESTER HEURISTIC
Step 1: Construct precedence diagram. Make a column I, in which include all work elements,
which do not have a precedence work element. Make column II in which list all elements, which
follow elements in column I. Continue till all work element are exhausted.

Step 2: Determine cycle time (T
c
) by finding all combinations of the primes of
N
i=1
T
iN

which is the total element time. A feasible cycle time is selected. Number of stations would be:
n =
N
i=1
T
iN
/ T
c

Step 3: Assign the work elements in the work stations so that total station time is equal to or
slightly less than the cycle time.

Step 4: Repeat step 4 for unassigned work elements



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5.7 TAKT TIME CALCULATION OF LARGE AIREND MODELS:

Total time = 600 minutes
Break time = 85 minutes
Total available time = 515 minutes

85% efficiency = 515*0.85 = 437.75 440 minutes
Demand of large air ends / days = 14

Takt time = Available time / demand
= 440 / 14
= 31.42 minutes 30 minutes