Operation Management | Product Layout Design | Assembly Line Balancing | Solved Example
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Product Layout Design: Line AssemblyProduct
Product Layout Design: Line Assembly
Product layout consists of a number of processes arranged one after another in a line to produce a standard product or service in a relatively high volume.
Uses specialized equipment or dedicated staff.
Each stage of production is able to maintain production at an equal rate.
Line balancing is used to ensure that the output of each production stage is equal and maximum efficiency is attained.
Line balancing ensures coordinated each stages of production and bottlenecks are avoided
A major design consideration in production lines is the assignment of operation so that all stages are more or less equally loaded.
The line-balancing problem is one of assigning all tasks to a series of workstations so that each workstation has no more than can be done in the workstation cycle time, and so that the unassigned (idle) time across all workstations is minimized.
Steps in balancing an assembly line:
1. Draw the precedence diagram.
2. Determine the required workstation cycle time CT,
CT =Production time per day/Required output per day (in units)
3. Determine the theoretical minimum number of workstations (Nt) required to satisfy the workstation cycle time: Nt = Sum of task times (T)/Cycle time (C)
4. Select a primary rule by which tasks are to be assigned to workstations, and a secondary rule to break ties.
5. Assign tasks, one at a time, to the first workstation until the sum of the task times is equal to the workstation cycle time, or no other tasks are feasible because of time or sequence restrictions. Repeat the process until all tasks are assigned.
6. Evaluate the efficiency of the balance derived using the formula
Efficiency = Sum of task times (T)/Actual number of workstations (Nt) × Workstations cycle time (CT)
7. If efficiency is unsatisfactory, rebalance using a different decision rule.
Product layout consists of a number of processes arranged one after another in a line to produce a standard product or service in a relatively high volume.
Uses specialized equipment or dedicated staff.
Each stage of production is able to maintain production at an equal rate.
Line balancing is used to ensure that the output of each production stage is equal and maximum efficiency is attained.
Line balancing ensures coordinated each stages of production and bottlenecks are avoided
A major design consideration in production lines is the assignment of operation so that all stages are more or less equally loaded.
The line-balancing problem is one of assigning all tasks to a series of workstations so that each workstation has no more than can be done in the workstation cycle time, and so that the unassigned (idle) time across all workstations is minimized.
Steps in balancing an assembly line:
1. Draw the precedence diagram.
2. Determine the required workstation cycle time CT,
CT =Production time per day/Required output per day (in units)
3. Determine the theoretical minimum number of workstations (Nt) required to satisfy the workstation cycle time: Nt = Sum of task times (T)/Cycle time (C)
4. Select a primary rule by which tasks are to be assigned to workstations, and a secondary rule to break ties.
5. Assign tasks, one at a time, to the first workstation until the sum of the task times is equal to the workstation cycle time, or no other tasks are feasible because of time or sequence restrictions. Repeat the process until all tasks are assigned.
6. Evaluate the efficiency of the balance derived using the formula
Efficiency = Sum of task times (T)/Actual number of workstations (Nt) × Workstations cycle time (CT)
7. If efficiency is unsatisfactory, rebalance using a different decision rule.
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