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Assembly Line Balancing

This document discusses assembly line balancing to maximize productivity. It provides an example of balancing tasks for 11 tasks in an assembly process. The tasks have precedence relationships and specified times. It describes calculating the desired cycle time based on production demands. An assembly line balancing heuristic is then shown that assigns tasks to 6 stations in a way that balances task times across stations to minimize idle time, achieving an 80% efficiency.

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451 views13 pages

Assembly Line Balancing

This document discusses assembly line balancing to maximize productivity. It provides an example of balancing tasks for 11 tasks in an assembly process. The tasks have precedence relationships and specified times. It describes calculating the desired cycle time based on production demands. An assembly line balancing heuristic is then shown that assigns tasks to 6 stations in a way that balances task times across stations to minimize idle time, achieving an 80% efficiency.

Uploaded by

zakria100100
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Assembly Line Balancing

Assembly Operation
Assembly operation is the process of
combining the parts of a product in a
systematic and orderly fashion. One of the
important tasks in manufacturing
environment is to design assembly lines in
such a way that the demand for the products
are met and the productivity of the assembly
line is maximized.

Example
Consider a product whose assembly process involves 11
tasks whose immediate predecessors and times are listed in
the table below.
TASK NUMBER

1
2
3
4
5
6
7
8
9
10
11

IMMEDIATE
PREDECESSOR
1,2
2
4
3
6
6
5,7
8,9
10

TASK TIME (minutes)

0.4
0.7
0.5
0.4
0.7
0.2
0.1
0.3
0.4
0.5
0.6

Precedence Diagram
1

10

11

Desired Cycle Time


suppose that a production rate of 1,300 units per
day is desired. And the factory will operate three
shifts per day. Therefore, operating three shifts per
day at a 90 percent efficiency amounts to
approximately (1,300/3) = 433 units per shift
productive capacity.
To estimate the required cycle time we first
compute the productive hours for each shift. This is
(8 hours per shift)(0.9 efficiency) = 7.2 hours per
shift. Thus, the desired cycle time is given by
C = [(7.2 hrs. per shift)x(60 min. per
hour)]/(number of units per shift required)
C = (7.2)x(60)/433 = 0.9977 min.

Assembly Line Balancing


Heuristic
Assignable
Job
Task
1
2

1
4

Sum of task time


at this Station

Time
0.4
0.7

Assignable
Job
Task

Tasks already
assigned to
Station 1

Tasks already
assigned to
Station 1

Sum of task time


at this Station

Time

0.4
0.4

0.7

Assembly Line Balancing


Heuristic
Assignable
Job
Task
4
3

4
6

Sum of task time


at this Station

Time
0.4
0.5

Assignable
Job
Task

Tasks already
assigned to
Station 2
1

Tasks already
assigned to
Station 2

0.4

Sum of task time


at this Station

Time

0.4
0.2

1, 3

0.9

Assembly Line Balancing


Heuristic
Assignable
Job
Task
5
6

5
8
7

Sum of task time


at this Station

Time
0.7
0.2

Assignable
Job
Task

Tasks already
assigned to
Station 3
4

Tasks already
assigned to
Station 3

0.4

Sum of task time


at this Station

Time
0.7
0.3
0.1

4, 6

0.6

Assembly Line Balancing


Heuristic
Assignable
Job
Task
5
7

5
9

Sum of task time


at this Station

Time
0.7
0.1

Assignable
Job
Task

Tasks already
assigned to
Station 3
4, 6, 8

Tasks already
assigned to
Station 3

0.9

Sum of task time


at this Station

Time

0.7
0.4

4, 6, 8, 7

1.0

Assembly Line Balancing


Heuristic
Assignable
Job
Task
9

10

Sum of task time


at this Station

Time
0.4

Assignable
Job
Task

Tasks already
assigned to
Station 4
5

Tasks already
assigned to
Station 5

0.7

Sum of task time


at this Station

Time

0.5

0.4

Assembly Line Balancing


Heuristic
Assignable
Job
Task
11

Tasks already
assigned to
Station 5

Sum of task time


at this Station

Time
0.6

9, 10

0.9

Station Assignment
STATION

TASKS
ASSIGNED

1
2
3
4
5
6

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

SUM OF
TASK
TIMES
0.7
0.9
1.0
0.7
0.9
0.6

IDLE TIME

0.3
0.1
0.0
0.3
0.1
0.4

Efficiency

Line efficiency =
(0.7+0.9+1.0+0.7+0.9+0.6)/[(1.0)x(6)] = 0.80

Therefore, this line will operate at 80 percent


efficiency and it will stay idle 20 percent of the time.

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