IPE 4102 FACILITY

LOCATION DESIGN AND

MATERIAL HANDLING

Line balancing in a production line

INTRODUCTION
Line balancing is the process of assigning tasks to
workstations in such a way that workstations have
approximately equal time requirements.
The goal of line balancing is to obtain task groupings that
represent approximately equal time requirements. This
minimizes the idle time along the line and results in a high
utilization of labor and equipment. Idle time occurs if task
times are not equal among workstations; some stations are
capable of producing at higher rates than other.
Line balancing involves assigning tasks to workstation.
Usually, each workstation has one worker who handles all of
the tasks at the station although an option is to have several
workers at the a single workstation.
The maximum time allowed at each workstation to complete
its set of tasks on a unit is called its cycle time.

2
 LINE BALANCING

We visited a silver utensils manufacturing factory in Newmarket, Jashore.

The daily desired output is 40 units/day.
The factory runs for 8 hours and total working hour is 6 hours a day.

3
 DATA

Processes Time (Minutes) Predecessors

Rolling 4 min None

Sheet cutting 6 min Rolling

Punching 2 min Sheet Cutting

Turning 3 min Punching

Logo Punching 1 min Turning

Finishing 5 min Logo Punching

Washing 8 min Finishing

4
 PRECEDENCE DIAGRAM

Rolling Sheet Logo

Punching Turning Finishing Washing
Cutting Punching

5
 FLEXSIM SIMULATION OF PRODUCTION LINE

20XX PRESENTATION TITLE 6

 CALCULATION

Minimum cycle time=8 minutes

Maximum cycle time=29 minutes
Desired Output rate= unit/minutes
Cycle Time, c=
Theoretical Minimum number of Workstation TM=4
Idle Time I=nc- t= 4*9-29=7 minutes
Efficiency, e==66.35%
Balance Delay= 100-66.35=33.65%
Efficiency before line balancing=

7
 LINE BALANCING
Work Station Task in Order Task Selected Workstation Time Idle Time

1 Rolling Rolling 4 minutes (9-4)=5 minutes

2 Plate Cutting Plate Cutting 6 minutes (9-6)=3 minutes

Punching Punching 2 minutes (3-2)=1 minutes

3 Turning Turning 3 minutes (9-3)=6 minutes

Logo Punching Logo Punching 1 minutes (6-1)=5 minutes

Finishing Finishing 5 minutes (5-5)=0 minutes

4 Washing Washing 8 minutes (9-8)=1 minutes

8
 CLUSTERING PROCESS

Sheet Turning
Rolling Cutting
Logo Washing
c Punching
Punching
Finishing

Station 1 Station 2 Station 3 Station 4

Time 4 min Time 8 min Time 9 min Time 8 min
Idle time 5 min Idle time 1 min Idle time 0 min Idle time 1 min

9
FLEXSIM SIMULATION OF BALANCED PRODUCTION LINE

PRESENTATION TITLE 10
 BAR CHART OF PRODUCTION LINE
9

5
Minutes

0
Rolling Sheet cutting Punching Turning Logo Punching Finishing Washing

Workstations

11
 BAR CHART OF BALANCED PRODUCTION LINE

6
Time(minutes)

0
Workstation 1 Workstation 2 Workstation 3 Workstation 4

Workstations

12
 RESULTS AND CONCLUSION

By plotting the time and workstations in the bar chart, we can conclude that before line balancing the idle time
for each workstation is very much. After the production line is properly balanced the ideal time for each
workstation increases and the efficiency of the overall process also increases.

13
THANK YOU

14