LINE BALANCING &

WORKER AND MACHINE

PROCESS CHART

Definisi
Line balancing merupakan suatu metode
penugasan sejumlah pekerjaan yang
saling berkaitan dalam satu lini produksi
sehingga setiap stasiun kerja memiliki
waktu yang tidak melebihi waktu siklus
dari stasiun kerja tersebut.
Line balancing berusaha menyeimbangkan
seluruh lintasan yang ada dalam lini
perakitan sehingga aliran produksi
berjalan lancar.

How to Calculate Line Efficiency ?

Standard Minutes
Operator
to Perform
Operation
1
2
3
4
5

0.49
0.31
0.25
0.44
0.54

Operator 4

Operator 3

Operator 5
Operator 1
Operator 2

Line Efficiency ?
Standard Minutes
Allowed
Wait Time Based on
Operator
to Perform
Standard
Slowest Operator
Operation
Minutes
1
2
3
4
5

0.49
0.31
0.25
0.44
0.54

0.05
0.23
0.29
0.1
0

2.03

2.7

S .M .
1
5

A.M
1

0.54
0.54
0.54
0.54
0.54

X 100

Opportunities for Improvements ?

Standard Minutes
Allowed
Wait Time Based on
Operator
to Perform
Standard
Slowest Operator
Operation
Minutes
1
2
3
4
5

0.49
0.31
0.25
0.44
0.54

0.05
0.23
0.29
0.1
0

0.54
0.54
0.54
0.54
0.54

2.03

2.7
Efficiency

75.19%

0.44
0.54

0.25

0.49

0.31

Assembly Line

(7 operations)
Operation Standard Minutes
1
1.5
2
2.25
3
1.25
4
2.5
5
3
6
2.75
7
1.75

Desired Rate of Production = 1000/day

Efficiency = 95%
1 day = 10 hours = 600 minutes
Thus R = 1000/600 = 1.67 units/minute

Numbers of Operator Needed

in Assembly Line?

SM

N R AM R
Operation

Standard Minutes

1
2
3
4
5
6
7

1.5
2.25
1.25
2.5
3
2.75
1.75

minutes/unit

0.6

SM
R
E

15
1.67
0.95
26.36842105

27 operators

Output?
Operation
1
2
3
4
5
6
7

minutes/unit

1.5/0.6
2.25/0.6
Dst.

(standard
Standard Minutes minutes)/(minutes/u Operators
nit)
1.5
2.5
3
2.25
3.75
4
1.25
2.083333333
2
2.5
4.166666667
5
3
5
5
2.75
4.583333333
5
1.75
2.916666667
3
0.6

600/1000

27

Slowest One?
Operation
1
2
3
4
5
6
7

(standard
Standard Minutes minutes)/(minutes/u Operators
nit)
1.5
2.5
3
2.25
3.75
4
1.25
2.083333333
2
2.5
4.166666667
5
3
5
5
2.75
4.583333333
5
1.75
2.916666667
3

(2.5/3)*0.6
(3.75/4)*0.6
Dst.

0.5
0.5625
0.625
0.5
0.6
0.55
0.583333333

5 60
output
100 / hour 1000 / day
3

Line Balancing Problem

3.4 mins

B
E

2.2 mins
A

2.7 mins

C
4.1mins
D

1.7mins

3.3
mins

2.6 mins

Question
1. What process is the bottleneck?
2. How much is the maximum
production per hour?
3. How much the efficiency?
4. How to minimize work stations?
5. How should they be grouped?
6. New efficiency?

A. 73.2%
B. 56.7%
C. 69.7%
D. 79.6%
E. 81.2%

Calculate efficiency
3.4 mins

B
E

2.2 mins

2.7 mins

C
4.1mins
D

1.7mins

3.3
mins

2.6 mins

(2.2+3.4+4.1+2.7+1.7+3.3+2.6)
4.1x7
20
28.7
69.7%
1-69.7%=30.3% Balance Delay

Number of Workstation

task times

N
cycle time (bottleneck)
20
= 4.88 work stations
4.1

4 Stations

20/24=83.3%

Line Balancing Solution

(5.6)

3.4
B

Station 1

Max prod./hour
60/6
Station 3
10 units/hour
E

2.2

2.7

4.1
Station 2

(5.8)
All under 6 minutes?

(6.0)
Station 4

1.7

3.3

2.6

5 Stations

Line Balancing Problem

3.4 mins 20/5.6x5 = 20/28 = 71.4%

5.6

B
E

2.2 mins

2.7 mins

C
4.1mins

Max Prod./hour
60/5.6
10.7 units/hour

1.7mins

3.3
mins

2.6 mins

5.0

40 secs

What is the minimum # of work stations?

Round down.
59 secs

34 secs

84 secs

3
2
4
5
6

56 secs

45 secs

task times

N
cycle time

40+59+84+56+34+45 = 318
318/84 = 3.78 or 3 work stations

What is the efficiency with 6 operators?

Efficency %

task times

number of stationscycle time

318/6 x 84=
318/504 =
63%

100

99 secs

3 Stations ?

40 secs

118 secs
59 secs
34 secs

84 secs

318/3x118

56 secs

45 secs

318/354 = 89.8%

Efficency %

task times

101 secs

number of stations cycle time

100

99 secs
40 secs

4 Stations?
84 secs

79 secs

59 secs
34 secs

84 secs

318/4 x 99 =
318/396 =
80.3%

56 secs
56 secs

45 secs

Worker and Machine Process

Chart

Worker and Machine Process

Chart
Definisi dan Kegunaan
Menggambarkan hubungan waktu
antara working cycle seseorang
dengan operating cycle suatu mesin
membandingkan idle mesin dengan
idle pekerja

Worker and Machine

Process Chart
Contoh:
man

Machine 1

loading

loading

Machine 2

walking
press
loading

walking

loading
idle
press

Worker and Machine Process

Chart

lm
N1
l w
N = jumlah mesin
m = total machine running time
w = walking time

l = loading and unloading time

Worker and Machine Process

Chart
total expected cost (TEC)
TECN1

(l m)( K1 N1 K 2 )

N1

TECN2 (l w)( K1 N 2 K 2 )
K1 = operator rate
K2 = cost of machine

Worker and Machine Process

Chart
contoh soal
proses

Time
(minute)

Pick up plate into press dies

Lubricate dies in press

0,1
0,3

Press
Walk to next press
$ worker (K1) = $ 12 / hour
$ machine (K2) = $ 10 / hour

1,2
0,1

Worker and Machine Process

Chart
Ditanya:
Jumlah mesin yang dibutuhkan
TEC tiap kemungkinan jumlah mesin

Jawaban
N = (l+m)/(l+w) = (0.4+1.2)/
(0.4+0.1) = 3.2
Sehingga jumlah mesin yang
mungkin adalah 3 atau 4 mesin

Jawaban
TEC3 = (l+m)(K1+n1K2)/n1
= (0.4+1.2)(12+3 x 10)/3/60
= $ 0.3733/ unit

TEC4 = (l+w)(K1+n2K2)
= (0.4+0.1)(12+4x 10)/60
= $ 0.4333 /unit