PRODUCT LAYOUT

Product Layout
• Flow arranged according to processing
sequence of the product, with relatively stable
requirements and standardized, repetitive
processing
• Objective: Smooth, rapid, high-volume flow
 Product Layout
• Work is divided into series of standard tasks,
permitting specialization

• Large volumes needed to make investments

worthwhile

• Key design issues:

– Allocation of work between workers/ workplaces
– Layout and handling
Product Layout (text p.414)

Boeing 737
2 inches per minute
 Implications of Product Layout
• Advantages:
– Throughput rate
– De-skilling and automation
– Simpler handling
– Easier to operate and control

• Limitations:
– Limited flexibility
– Vulnerable to disruption of operations
– Effect on resource utilization?
 Production (Assembly) Lines
• A common form of Product Layout

• Even non-technical products/ services require

assembly-like operations

• Pre-dominantly manual work, though

progressively getting mechanized/ automated
Line Balancing Approach,
Algorithm & Example

Chapter 9 contd.
 5. Line Balancing
“For instance, the first worker could cut the cloth, the
second worker put in the first stitch, the third sews buttons
and so on so forth.
..
This breakdown of tasks is called an assembly line. But
you have to ensure that each task is of equal time to avoid
bottlenecks.
..
In typical IIT fashion, the simple example somehow
converted into complex equations. The prof gave an
assignment for the next class using these equations,
which meant two hours at least in the library that night.”
Manufacturing According to Henry Ford

“Any Color - So Long As It's Black.”

"How Come When I Want A Pair Of Hands,

I Get A Human Being As Well?"
 Snapshots: On Numbers
“You didn't run the numbers?
But this is Business school.
This institution is about running numbers.
You and your group had better run the numbers
right now.
The rest of us will wait.

Thus began the most excruciating hour of my life.”

[Note: This was in a case-based Marketing class!]

 Line Balancing Terminology
RM
Stn. 1 Stn. 2 Stn. 3
FG

• Task/ Element: Small, distinct subset of work, taking time ti

• Station: Place where a set of one or more task(s) are performed
• Cycle Time (c): Time interval between flow of successive units =
time available at a single stage for performing the assigned
tasks
• Station Time (STj): Sum of task times assigned to a station (STj < c)
• Throughput Rate TH: Average rate (per unit time) at which units are
processed
TH = 1/c
 Line Balancing Terminology:
Precedence
Relationship that specifies the order in which
which tasks must be performed, i.e. which tasks
must be completed before a task can begin
Immediate
Activity Predecessor
1 - 1 3
2 -
5
3 1,2
4 2
5 3,4
2 4
Line Balancing Example from
Heizer Text
 Wing Component Example
Performance Task Must
Follow
Time Task Listed
Task (minutes) Below
A 10 —
B 11 A This means that
C 5 B tasks B and E
cannot be done
D 4 B until task A has
E 11 A been completed
F 3 C, D
G 7 F
H 11 E
I 3 G, H
Total time 65
Table 9.2
(p. 415)
 Wing Component Example
Performance Task Must
Follow
Time Task Listed
Task (minutes) Below
A 10 —
B 11 A
C 5 B Figure 9.12
(p. 415)
D 4 B
E 11 A
F 3 C, D 5

G 7 F 10 11
C
3 7
H 11 E
A B F G
I 3 G, H 4
3
Total time 65 D I
11 11
E H
 Line Balancing
• The assignment of tasks to stations in a line so
as to achieve the desired output rate with
smallest number of stations, each of which have
nearly equal time requirements.

• Constraints in line balancing:

– Precedence requirements (order of operations)
– Cycle time restrictions (the maximum operating time
allowed for each workstation)
• Depend on demand rate, production time
 Line Balancing Approach

• Draw and label the precedence diagram

• Calculate the desired cycle time required for
the line
• Calculate the theoretical minimum number of
workstations
• Group elements into work stations recognizing
cycle time & precedence
• Calculate ‘efficiency’ of the line

Refer Text p. 416, 418

 Line Balancing Assumptions
• Identical products with no changeover times
• A station can work on only one product unit at a
given instant
• A product unit can be on only one station at a
given instant
• One operator per station
• Accurate, deterministic task times
• All operators are uniformly skilled or efficient
• Lower bound cycle time?
 Basic Relationships ..
Production time available per day
(Reqd.) Cycle time =
Units required per day

Minimum ∑
i = 1 Time for task i
number of =
workstations Cycle time

Refer Text Eq. 9.4, 9.5 [also 9.2, 9.3];

(p. 416)
 Wing Component Example
Performance Task Must 480 available
Follow mins per day
Time Task Listed 40 units required
Task (minutes) Below
A 10 —
B 11 A Production time
C 5 B available per day
D 4 B Cycle time = Units required per day
E 11 A = 480 / 40
5
F 3 C, D = 12 minutes per unit
G 7 F n C
10 11 3 7
H 11 E
A i∑ = 1Time
B for taskFi G
I 3 G, H Minimum 4
number of = 3
Total time 65 workstations Cycle Dtime
11 11 I
= 65 / 12
E H
= 5.42 or 6 stations
p.417
 General Approach of Single-Pass
Line Balancing Heuristics
• Load one station at a time, assigning tasks to
the station until it is filled as much as possible.
• Order of task consideration/ selection:
1. Precedence (All predecessors already assigned)
2. Fitment (Task Time ≤ Unused Station Time)
3. Priority rule (heuristic e.g. Longest Task, Most
Followers, Ranked Positional Weight etc.) - to
choose between qualifying tasks
• When station cannot be filled any further, close
it and start next station
• Continue until all tasks assigned.
 Line-Balancing Heuristics
1. Longest task time Choose the available task with the
longest task time

2. Most following tasks Choose the available task with the

largest number of following tasks

3. Ranked positional weight Choose the available task for which

the sum of its own time plus the
times of each following task is the
longest

4. Shortest task time Choose the available task with the

shortest task time

5. Least number of following Choose the available task with the

tasks least number of following tasks

Text Table
9.3 (p. 416)
 Wing Component
Line-Balancing Example
Heuristics

1. Longest task time Choose the available task with the

480 available
Performance Task Must longest task time
Follow mins per day
Time
2. MostTask Listed
following tasks 40 units
Choose the available required
task with the
Task (minutes) Below largest number of following tasks
A 10 — Cycle time = 12 mins
B 11 A Minimum
C 5 3. BRanked positional weight Choose the available
workstations
task for
= 5.42 or 6
which the sum of its own time
D 4 B plus the times of each following
E 11 A task is the longest
F 3 C, D
G 7 4. FShortest task time Choose the available task with the
shortest task time
H 11 E
I 3 5. G, H number of following
Least Choose the available task with the
tasks least number of following tasks
Total time 65

Text Table
9.3 (p. 416)
 Wing Component Example
Performance Task Must 480 available
Follow mins per day
Time Task Listed 40 units required
Task (minutes) Below
A 10 — Cycle time = 12 mins
B 11 A Minimum
Station
workstations = 5.5 or 6
C 5 B 2 5
D 4 B C
E 1011 A 11 3 7
F A 3 C, B D F G
4 3
G 7 F
D Station 3
H 11 E I
I 3 G, H 11 11
Total time 65 Station 6
Station
1 E H
Station Station Figure 9.13
4 5
(p. 417)
 .. Basic Relationships
Production time available per day
(Reqd.) Cycle time =
Units required per day

Minimum ∑
i = 1 Time for task i
number of =
workstations Cycle time

∑ Task times
Efficiency =
(Actual number of workstations) x Cycle time

Idle Time = (Actual no. of workstations X Cycle time) – ∑Task times

Refer Text Eq. 9.4, 9.5 [also 9.2, 9.3];

9.6, 9.7 (p. 416-418)
 Wing Component Example
Performance Task Must 480 available
Follow mins per day
Time Task Listed 40 units required
Task (minutes) Below
A 10 — Cycle time = 12 mins
B 11 A Minimum
C 5 B workstations = 5.42 or 6
D 4 B
E 11 A
F 3 C, D
G 7 F ∑ Task times
Efficiency =
H 11 E (Actual number of workstations) x (Cycle time)
I 3 =G,65Hminutes / (6 stations) x (12 minutes)
Total time 65
= 90.3%
Idle Time = 6 x 12 – 65 = 7 mins
 About Such Heuristic Algorithms
• Performance of such solution methods varies
with problem data, secondary tie-breaking rules
used etc. due to heuristic nature (no guarantee
of optimality, since filling one station at a time
greedily)

• Plethora of such decision rules in literature:

choice/ blend limited only by time and creativity!

• Note: Rules are applied only when there is a

choice
Also see (simpler) Solved Problem 9.2 in Text, p. 423
Another Line Balancing
Example
 Line-Balancing Heuristics
1. Longest task time Choose the available task with the
longest task time

2. Most following tasks Choose the available task with the

largest number of following tasks

3. Ranked positional weight Choose the available task for which

the sum of its own time plus the
times of each following task is the
longest

4. Shortest task time Choose the available task with the

shortest task time

5. Least number of following Choose the available task with the

tasks least number of following tasks

Text Table
9.3 (p. 416)