Product Layout

All products go through one sequence of operations. Assembly line production is a good example.

Line Balancing: Purpose is to balance a line , which means equal time at each station. Each station may have more than one operation. Sometimes we may not be able to balance a line perfectly because: (i) operation times are fixed (can not be sub divided) (ii) precedence relationships ------ drill before tap (iii) people/equipment factor ------ not at same rate

Example:

Toy Factory; Assemble Model K23675 Wagon

Task # 1.

Description Position rear axle support and hand fasten four screws to nuts Insert rear axle Tighten rear axle support screws to nuts Position front axle assembly & and hand fasten four screws to nuts. Tighten front axle assembly screws Position rear wheel(#1) and fasten hub cap Position rear wheel (#2) and fasten hub cap Position front wheel (#1) and fasten hub cap Position front wheel (#2) and fasten hub cap Position handle shaft on front axle assembly and hand fasten bolt & nut Tighten bolt and nut

Time(Minutes) Task that must preceed

0.75 0.18

* 1

2. 3.

0.15

1,2

4.

0.83

5.

0.25

6.

0.20

1,2,3

7.

0.20

1,2,3

8.

0.20

4,5

9.

0.20

4,5

10.

0.13 0.15

1,2,3,..........8,9 10

11.

0.20 0.18 0.75 0.15

6
0.20

3 7
0.13 0.15 11

0.83

0.25

0.20

10

8
0.20

9
N

Total Cycle Time = T = 3 ti = t1 + t2 + .... t13

i =1

= 0.75 + 0.18 + .... + 0.15 = 3.24 minutes Assume one shift operation = 8 hours = (60)(8) = 480 minutes Time allowed for breaks = 60 minutes Total productive time = P = 420 minutes/day Let us assume, we need to produce 500 wagons per day. Demand per day = D =500

Cycle time = C =

P 420 = = 0.84 minutes Demand 500

For a cycle time of C, minimum number of work station, N, is

N =

T 3.24 = = 3.86 need 4 Cycle Time 0.84

For a minimum number of 4 work stations, how to group the eleven different operation at each station? This grouping must satisfy the precedence relationship and total time at each station cannot exceed 0.84 minutes.

Kilbridge and Websters Heuristic

1. Rank order operations according to number of predecessors. 2. Operations with least number of predecessors are assigned first. 3. In case of a tie, choose operation with longest operation time. 4. Total time at each work station should not exceed cycle time. 5. Precedence relationships must be satisfied. *************************************************************** Develop rank order for all operations Rank 1 2 3 4 5 6 7 8 9 10 11 Operation 1 4 2 5 3 8 9 6 7 10 11 No of Predecessors 0 0 1 1 2 2 2 3 3 9 10 Time (ti) 0.75 0.83 0.18 0.25 0.15 0.20 0.20 0.20 0.20 0.13 0.15

Assignment of Operations To Work Stations 1. Work Station # 1 Two with least predecessors (none) which are 1 & 4 Choose operation # 4 ----- it has longest time Unassigned Time = 0.84 - 0.83 = 0.01 Time for remaining operations is greater than 0.01 2. Workstation # 2 Assign operation # 1 (least predecessors = none) Unassigned time = 0.84 - 0.75 = 0.09 Time for remaining operations is greater than 0.09 3. Work Station # 3 (i) Two with operations least predecessors (one) which are 2 & 5 Assign # 5 ------- longest time Unassigned time = 0.84 - 0.25 = 0.59 As time for operation # 2 is less than 0.59, it can be assigned to this station Unassigned time = 0.59 - 0.18 = 0.41 (ii) Feasible Operations after # 5 and # 2 have been assigned None has one predecessor while # 3, # 8 and # 9 have two predecessors First assign # 8 or # 9 due to longer time (0.20 > 0.18) Assign # 8 first as it has lower operation number (# 8 < # 9) Unassigned time = 0.41 - 0.20 = 0.21

Next assign # 9 and Unassigned time = 0.21 - 0.20 = 0.01 All other operation times are greater than 0.01

4. Workstation # 4 (i) Assign # 3 first as it has only two predecessors Unassigned time = 0.84 - 0.15 = 0.69 (ii) Operations # 6 and # 7 have three predecessors Assign 6 first (lower operation #); Unassigned time = 0.69 - 0.0.20 = 0.49 Assign 7 next; Unassigned time = 0.49 - 0.20 = 0.29

(iii)

Assign # 10 next at it has 9 predecessors Unassigned time = 0.29 - 0.13 = 0.16

(iv)

Assign # 11 Unassigned time = 0.16 - 0.15 = 0.01

Work Station

Operation

ti

Remaining Unassigned Time 0.84-0.83=0.01 0.84-0.75=0.09 0.84-0.25=0.59 0.59-0.18=0.41

Feasible Remaining Operations None All t i> 0.01 None All t i>0.09 2,8,9 3,8,9

Task with Least Predecessors * * 2 3,8,9

Task With Longest ti * * * 8,9

Remarks

1 2 3

4 1 5 2

0.83 0.75 0.25 0.18

Break Tie Longest ti * * Break Tie Longest t i & Lowest opns # Longest t i * Break Tie, Lowest opns # * * *

8 9 4 3 6 7 10

0.20 0.20 0.15 0.20 0.20 0.13

0.41-0.20=0.21 0.21-0.20=0.01 0.84-0.15=0.69 0.69-0.20=0.49 0.49-0.20=0.29 0.29-0.13=0.16

3,9 None All t i>0.01 6,7,60 7,10 10 11

3,9 * 6,7 7 * *

9 * 6,7 * * *

Helgeson & Bernies Method

Positional Weight = Time of operation + times of all operations that must follow it Method: 1. Assign operation with highest positional weight first 2. If a tie, break it using (i) higher operation time (ii) lower operation number 3. Total time at a station can not exceed cycle time 4. Precedence relationship must be satisfied

Example:

Toy wagon Assembly.

Calculate positional weight for each operation. Operation # 1 PW = time for number 1 + 2 + 3 + 6 + 7 + 10 + 11 = 0.75 + 0.18 + 0.15 + 0.20 + 0.20 + 0.13 + 0.15 = 1.76

Operation # 2 PW = PW for number 1 - time for # 1 = 1.76 - 0.75 = 1.01 Similarly PW for number 3 = PW for # 3 - time for # 2 = 1.01 - 0.18 PW for # 4 = time for number 4 + 5 + 8 + 9 + 10 + 11 = 1.76 PW for # 5 = PW for number 4 - time for # 4 = 0.93 PW for # 6 = time for # 6 + 10 + 11 = 0.48 PW for # 7 = time for # 7 + 10 + 11 = 0.48 PW for # 8 = time for # 8 + 10 + 11 = 0.48 PW for # 9 = time for # 9 + 10 + 11 = 0.48 PW for # 10 = time for # 10 + 11 = 0.28 PW for # 11 = time for # 11 = 0.15

1. Work Station number 1 Highest positional weight 1.76 for operations number 1 and 4. Break tie using higher time ------ assign 4 Unassigned time = 0.84 - 0.83 = 0.01

2. Work Station number 2 Assign # 1 with positional weight of 1.76 Unassigned time = 0.84 - 0.75

3. Work Station number 3 Assign # 2 with PW = 1.01; Assign # 5 with PW = 0.93; Assign # 3 with PW = 0.83; Assign # 6 with PW = 0.48; 4. Work Station number 4 All operations, # 7, 8, 9 , 10 have PW = 0.48 Break tie using lower operation number Assign 7; Assign 8; Assign 9; Assign 10; Unassigned time = 0.84 - 0.20 = 0.64 Unassigned time = 0.64 - 0.20 = 0.44 Unassigned time = 0.44 - 0.20 = 0.24 Unassigned time = 0.84 - 0.20 = 0.04 Unassigned time = 0.83 - 0.18 = 0.66 Unassigned time = 0.66 - 0.25 = 0.41 Unassigned time = 0.41 - 0.15 = 0.26 Unassigned time = 0.26 - 0.20 = 0.06

5. Work Station number 5 Need this work station as all operations are not assigned Assign 11; Unassigned time = 0.84 - 0.15 = 0.69 Number of Workstation and Efficiency 1. Cycle Time Maximum total time allowed at each work station Minimum cycle time is tmax

Work Station 1 2 3

Opns

P.W.

Immediate Predecessor None None 1 4 1, 2 1, 2, 3 1, 2, 3 4, 5 4, 5 6, 7, 8, 9 10

Opn Time 0.83 0.75 0.18 0.25 0.15 0.20 0.20 0.20 0.20 0.13 0.15

Station Time Cumulative 0.83 0.75 0.18 0.18+0.25 = 0.43 0.43+0.15 = 0.58 0.58+0.20 = 0.78 0.20 0.40 0.60 0.73 0.15 Unassigned 0.84-0.83 = 0.01 0.84-0.75 = 0.09 0.84-0.75 = 0.66 0.66-0.25 = 0.41 0.41-0.15 = 0.26 0.26-0.20 = 0.06 0.84-0.20 = 0.64 0.64-0.20 = 0.44 0.44-0.20 = 0.24 0.24-0.13 = 0.11 0.84-0.15 = 0.69

4 1 2 5 3 6

1.76 1.76 1.01 0.93 0.83 0.48 0.48 0.48 0.48 0.28 0.1

7 8 9 10

11

where tmax = maximum operation time for one element tmax minimizes cycle time but number of work station is higher Maximum cycle time is = 3ti
i=1 n

Only one work station and all operation are done on it 2. Minimum number of work stations for a given cycle time Cycle time can be determine to produce a given quantity (Demand)

Cycle Time =

Productive Time / day Demand / day

In one day, # of minutes = 480 minutes Time allowed for breaks = 60 minutes Productive time/day = 480 - 60 = 420 minutes

Let demand equals 240 unit/day

Cycle Time =

420 = 175 minutes . 240

Let 3ti = sum of all operation time = 4 minutes; then

Minimum number of work station =

We will need at least 3 station 3. Maximum Efficiency

4 = 2.28 3 1.75

Maximum Efficiency = Emax =

ti NC

where N = number of station for a given cycle time C = cycle time For our example; toy wagon D = 500/day 3ti = 3.24

Cycle Time =

420 = 0.84 minutes 500 3.24 = 385 4 . 0.84

Minimum number of WS =

Max Efficiency =

ti 3.24 = = 96.4% NC 4( 0.84)

4.

Actual Efficiency

Actual Efficiency =

ti MC

Where M = Actual number of work stations For Helgeson and Bernie method; M=5

Actual Efficiency =

3.24 = 771% . 5(0.84)

An Example

3ti = 0.32 + 0.10 + ......... + 0.30 = 1.97

PW for 00; =

0.32 + 0.20 + 0.23 + 0.05 + 0.2 + 0.32 + 0.30 = 1.72 [ or 1.97 - (0.10 + 0.05 + 0.10) = 1.72 ]

PW for 01; = 1.97 - 0.32 = 1.65

PW for 02 = 1.40 PW for 03 = 0.87 PW for 04 = 0.82 PW for 05 = 1.20 or (0.23 + 0.05 + 1.2 + 0.32 + 0.10 + 0.3) PW for 06 = 0.92 PW for 07 = 0.45 PW for 08 = 0.72 PW for 09 = 0.40 PW for 10 = 0.30

As 3ti = 1.97 Minimum number of stations = 1, cycle time = 1.97

Maximum operation time = 0.32

Max number of Stations =

1.97 6.2 cycle time = 0.32 0.32

Can assign one element at each work station resulting in ten workstations but not a good idea. ************************************************

Operations arranged according to positional weights

OPN 00 01 02 05 06 03 04 08 07 09 10

PW 1.72 1.65 1.40 1.20 0.92 0.87 0.82 0.72 0.45 0.40 0.30

Rank 1 2 3 4 5 6 7 8 9 10 11

Time 0.32 0.10 0.20 0.23 0.20 0.05 0.10 0.32 0.05 0.10 0.30

Cycle time is one minute. Assignment using Helgeson and Birnies Method W.S 1 OPN 00 1 2 5 3 4 2 6 8 7 9 10 P.W 1.72 1.65 1.40 1.20 0.87 0.82 0.92 0.72 0.45 0.40 0.30 Immediate Predecessor * * 00 2 1 3 5 6 5 8 9 ti 0.32 0.10 0.20 0.25 0.05 0.10 0.20 0.32 0.05 0.10 0.30 Time Cumulative 0.32 0.42 0.62 0.85 0.90 1.00 0.20 0.52 0.57 0.67 0.97 Unassigned 0.68 0.58 0.38 0.15 0.10 0 0.80 0.48 0.43 0.33 0.03

Total unassigned time = 0.0 + 0.3 = 0.03

Efficiency =

ti 197 . = = 0.985 = 985% . ( N)(Cycle ) 2(1)

In our assignment we used a cycle time of one minutes. Time for all operation = 1.97 minutes For two workstations;

minimum cycle time =

1.97 = 0.985 2

Can we assign all operations to two workstations using a cycle time of 0.985 minutes? Look at our existing assignment Work Station number 1 ------ 00, 01, 02, 05, 03, 04 (Total time = one minutes) Operation 00, 01, 02 must be assigned at station number 1 due to precedence. Total time is 0.62. Next operation can be 05 or 03. Using H & B method, we assign 05. Note if 03 is assigned, only other operation that be can be assigned is 04. We have now, 00, 01, 02, and 05 (Time=0.85). We assign 03 (Note: 6 cannot be assigned) and total time is 0.90. For a cycle time of 0.985 ------- 04 can not be assigned. Only 07 can be assigned. Total time is 0.95. No other station can be assigned. Work Station number 2 ------ 04, 06, 07, 08, 09, 10 (Total time = 1.02 minutes) Can not have a cycle time of 0.985 Must use three workstations

Summary
1. Cycle time = 1.0 minutes Number of work stations = 2

Actual Efficiency =

1.97 = 98.5% 2.0

For one shift operation, allowing 60 minutes for break, production per day is 420 units.

2. If we want to increase production, using only one shift, cycle time must decrease. This means, increasing the number of work stations to three. 3. Cycle time for 3 work stations is
1.97 3

or 0.656 minutes

Production per day =

420 = 640 units 0.656

Can we assign all operations in three stations using a cycle time of 0.656 minutes? 4. We start with existing assignment, if we have one, and start reducing cycle time by a fixed amount. Let use 0.10 minutes. 5. Use cycle time of 0.90 minutes Work Station number 1: 00, 01, 02, 05, 03 (Time=0.901) Work Station number 2: 04, 06, 08, 07, 09 (Time=0.77) Work Station number 3: 10 (Time=0.30)

6. Use cycle time of 0.80 minutes Work Station number 1: 00, 01, 02, 03, 04 (Time=0.77) Work Station number 2: 05, 06, 08, 07 (Time=0.80)

Work Station number 3: 09, 10 (Time=0.40) 7. Use cycle time of 0.70 minutes Work Station number 1: 00, 01, 02, 03 Work Station number 2: 05, 04, 06, 07 Work Station number 3: 08, 09 (Time=0.67) (Time=0.58) (Time=0.42)

As unassigned time = 0.70-0.42 = 0.28 , we need a 4th station

8. A cycle time of 0.70 minutes is not feasible with three work stations 9. Next, we increase cycle time from 0.70 minutes. Recall, we can use a cycle time 0.80 with

three station (Step number 6). We use an increase of 0.01 minutes 10. Using a similar process, a cycle time of 0.72 is feasible with following assignment. Work Station number 1: 00, 01, 02, 03) Work Station number 2: 05, 06, 04, 07) Work Station number 3: 08, 09, 10 11. For 3 Work Stations: Cycle time = 0.72 minutes Production =
420 0 .72 = 583 day

(Time=0.67) (Time=0.58)

(Time=0.72)

Actual efficiency =

1.97

( 2 )( 1) =

91.2%

For 2 Work Stations: Cycle time = 1.0 minutes Production =

420 1

420

day

Actual efficiency =

1.97

( 2 )( 1)

= 98.5%

12. Which one is better?