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Assembly
Dr Ateekh-Ur-Rehman
Refer Chapter 9 in Text Book
Assembly--Line Balancing
Assembly
Objective is to minimize the imbalance
between machines or personnel while
meeting required output
Starts with the precedence relationships
1.
2.
3.
Copier Example
Task
A
B
C
D
E
F
G
H
I
Performance
Time
(minutes)
10
11
5
4
12
3
7
11
3
Total time 66
A
B
B
A
C, D
F
E
G, H
Copier Example
Task
A
B
C
D
E
F
G
H
I
Performance
Time
(minutes)
10
11
5
4
12
3
7
11
3
Total time 66
A
B
B
A
C, D
F
E
G, H
5
10
11
C
4
12
G
3
11
H
Figure 9.13
Copier Example
Task
A
B
C
D
E
F
G
H
I
Performance
Time
(minutes)
10
11
5
4
12
3
7
11
3
Total time 66
A
Production time available
B
per day
CycleBtime =
Units required per day
A
= 480 / 40
5
C, D
= 12 minutes per unit
C
F
10
11
3
n
E
BTime for task i F
A
Minimum
G, H
i=1
4
number of =
Cycle time
workstations
12
= 66 / 12E
= 5.5 or 6 stations
11
H
Figure 9.13
Copier Example
Line-Balancing Heuristics
H
Table 9.4
Figure 9.13
Copier Example
Performance
Time
(minutes)
Task
A
10
B
11
Station
C
52
D
4
11
E 10
12
B
F A
3
G
7
H
11
I
3
Stationtime 66
Total
1
12
A
5
B
C B
A
C, D
4
F
D E
G, H
Station 4
I
11
Station
3
Station
5
Station 6
Figure 9.14
Copier Example
Task
Performance
Time
(minutes)
A
10
Example 2
Roll dough
Place on cardboard backing
Sprinkle cheese
Spread Sauce
Add pepperoni
Add sausage
Add mushrooms
Shrinkwrap pizza
Pack in box
None
A
B
C
D
D
D
E,F,G
H
Total task time
50
5
25
15
12
10
15
18
15
165
Layout Calculations
Step 2: Determine output rate
Vicki needs to produce 60 pizzas per hour
60 sec./unit
desired output units/hr
60 units/hr
available time
3600 sec./hr.
E lig ib le ta s k
A
B
C
D
E, F, G
E, F
F
H
I
T a s k S e le c te d
A
B
C
D
G
E
F
H
I
T a s k tim e
50
5
25
15
15
12
10
18
15
Id le tim e
10
5
35
20
5
48
38
20
5
(%)
NC
165 sec.
100 91.7%
3 stations x 60 sec.
Example 3
Task
Imm. predecessor
None
55
30
22
35
B, C
50
15
10
TOTAL
222
task description
operation
time (min)
must
follow
inspection
13
D, E
44
How often does a club need to come off the line in order to meet the
customer demand required?
Exclude initial start-up
Cycle time = (480 min/shift)/(24 clubs/shift) = 20 min/club
Takt time (for this example, same as cycle time as defined above)
Takt time = available work time/customer demand
Aligns output of a process with customer demand (or the pull
of the customer)
Takt is a German word referring to the rhythm or beat of
music
Theoretical minimum number of workstations for this operation
Total work content/cycle time
44 min/20 min per workstation = 2.2 workstations 3
workstations
stations
A, C
E, B, D
18 min
20 min
6 min
20 min
20 min
20 min
idle time
2 min
0 min
14 min
tasks
Example 5
Balancing manufacturing line
For a manufacturing line, the data below on the task precedence
relationships exist (assume the tasks cannot be split)
task
performance
time (min)
must
follow
C, B
D, E, F, G
Example 5
continue
Construct the precedence diagram for the tasks.
What is the theoretical minimum cycle time?
To balance the line to the cycle time determined
above, what is the minimum number of work
stations?
Use the "longest-operation-time" rule to balance
the line to the theoretical minimum cycle time
determined above.
Calculate the efficiency of the balanced line.