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06-3-Assembly Line Balancing
06-3-Assembly Line Balancing
06-3-Assembly Line Balancing
Ron Lembke
Operations
Belt Conveyor
PRECEDENCE DIAGRAM
Draw precedence graph
(times in minutes)
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LEGAL ARRANGEMENTS
A B
5 G
20 15
E I J
C D 8
12 7
H
5 10 F 12
3
Ok: AC|BD|EG|FH|IJ
ABG|CDE|FHI|J C|ADB|FG|EHI|J
NOT ok: BAG|DCH|EFJ|I
DAC|HFE|GBJ|I
LEGAL ARRANGEMENTS
A B CT = maximum of workstation times
5 G
20 15
E I J
C D 8
12 7
H
5 10 F 12
3
AC|BD|EG|FH|IJ = max(25,15,23,15,19) = 25
ABG|CDE|FHI|J = max(40,23,27,7) = 40
C|ADB|FG|EHI|J = max(5,35,18,32,7) = 35
AC BD EG FH IJ
CYCLE TIME
The more units you want to produce per hour, the less time a
part can spend at each station.
Cycle time = time spent at each spot
Nodes # after
Choose C first, then, if possible,
C 6 add D to it, then A, if possible.
D 5
A 4
B,E,F 3
G,H 2 A B G
5
20
I 1 E 15
I J
C D 8
H 12 7
5 10 F 12
3
PRECEDENCE DIAGRAM
Draw precedence graph
(times in seconds)
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
NUMBER OF FOLLOWING TASKS
Nodes # after A could not be added to first
station, so a new station must be
A 4 created with A.
B,E,F 3 B, E, F all have 3 stations after,
G,H 2 so use tiebreaker rule: time.
I 1 B=5
E=8
F=3
Use E, then B, then F.
A B
5 G
20 15
E I J
C D 8 7
H 12
5 10 F 12
3
PRECEDENCE DIAGRAM
E cannot be added to A, but E can be added
to C&D.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
PRECEDENCE DIAGRAM
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
PRECEDENCE DIAGRAM
Next priority B can be added to A.
Next priority F can’t be added to either.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
NUMBER OF FOLLOWING TASKS
Nodes # after
G,H 2 G and H tie on number coming after.
G takes 15, H is 12, so G goes first.
I 1
PRECEDENCE DIAGRAM
G can be added to F.
H cannot be added.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
PRECEDENCE DIAGRAM
I is next, and can be added to H, but J
cannot be added also.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
PRECEDENCE REQUIREMENTS
A B
5 G
20
15
E I J
C D 8
12 7
H
5 10 F 12
3
Why not put J with F&G?
AB CDE HI
FG J
CALCULATE EFFICIENCY
We know that at least 4 workstations will be
needed. We needed 5.
Sum of task times (T)
Efficiencyt =
Actual # WS * Cycle Time
= 97 / ( 5 * 25 ) = 0.776
We are paying for 125 minutes of work, where it
only takes 97.
LONGEST FIRST
Try choosing longest activities first.
A is first, then G, which can’t be added to A.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST
H and I both take 12, but H has more
coming after it, then add I.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST
D is next. We could combine it with G, which we’ll do later. E is next, so
for now combine D&E, but we could have combined E&G. We’ll also
try that later.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST
A B
5 G
20
15
E I J
C D 8
12 7
H
5 10 F 12
3
CT = 25, so efficiency is again
Eff = 97/(5*25) = 0.776
LONGEST FIRST- COMBINE E&G
Go back and try combining G and E instead
of D and E.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST- COMBINE E&G
J is next, all alone. C is added to D, and B is
added to A.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST- COMBINE E&G
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST - COMBINE D&G
Back up and combine D&G. No precedence violation.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST - COMBINE D&G
Unhook H&I so J isn’t stranded again, I&J is 19, that’s better than
7. E&H get us to 20. This is feeling better, maybe?
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
LONGEST FIRST - COMBINE D&G
5 Again! CT is again 25, so efficiency is again 97/(5*25) = 0.776
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
CAN WE DO BETTER?
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
CAN WE DO BETTER?
If we have to use 5 stations, we can get a
solution with CT = 20.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
CALCULATE EFFICIENCY
With 5 WS at CT = 20
Sum of task times (T)
Efficiencyt =
Actual # WS * Cycle Time
= 97 / ( 5 * 20 ) = 0.97
We are paying for 100 minutes of work, where
it only takes 97.
OUTPUT AND LABOR COSTS
With 20 min CT, and 800 minute workday
Output = 800 min / 20 min/unit = 40 units
Don’t need to work 800 min
Goal 32 units: 32 * 20 = 640 min/day
5 workers * 640 min = 3,200 labor min.
We were trying to achieve
4 stations * 800 min = 3,200 labor min.
Same labor cost, but more workers on shorter
workday
HANDLING LONG TASKS
If not:
Parallel workstations
use skilled (faster) worker to speed up
SUMMARY
Compute desired cycle time, based on Market
Demand, and total time of work needed
Methods to use:
Largest
first, most following steps, trial and error
Compute efficiency of solutions