Layout Line Balancing

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L ine Balancing

Green Grass , Inc .

Big B roadcaster

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L ine Balancing

I t is the assignment of Wor kstations

in a production line so as to achieve

the desired output rate with the

smallest number of Work- stations

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Assembly-Line Balancing

Object ive is to m inim ize the imbalance

between machines or personnel whi le

meet ing requ i red outpu t

Starts with the precedencerelat ionships

1. Determ ine cyc le time

2. Calcu late theoret ical

min imum number o fworkstat ions

3. Balance the line by

assign ing speci f ic

tasks to workstat ions

3

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L ine Balancing Big Broadcaster

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L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 AC Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 CH Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

Example 7.3

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

Example 7.3

7/30/2019 Layout Line Balancing

7/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

A

Example 7.3

7/30/2019 Layout Line Balancing

8/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

30

B

A

Example 7.3

7/30/2019 Layout Line Balancing

9/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

50

B

C

A

30

Example 7.3

7/30/2019 Layout Line Balancing

10/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

50

30

40

D

B

C

A

Example 7.3

7/30/2019 Layout Line Balancing

11/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

6

50

E30

40

D

B

C

A

Example 7.3

7/30/2019 Layout Line Balancing

12/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

6

50

E30

25

40

D

B

F

C

A

Example 7.3

7/30/2019 Layout Line Balancing

13/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

6

50

15

E30

25

40

D

B

F

C

A

G

Example 7.3

7/30/2019 Layout Line Balancing

14/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

6

20

50

15

E30

25

40H

D

B

F

C

A

G

Example 7.3

7/30/2019 Layout Line Balancing

15/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

A Bolt leg frame to hopper 40 None

B Insert impeller shaft 30 A

C Attach axle 50 A

D Attach agitator 40 B

E Attach drive wheel 6 B

F Attach free wheel 25 C

G Mount lower post 15 C

H Attach controls 20 D, E

I Mount nameplate 18 F, G

Total 244

Work Time Immediate

Element Description (sec) Predecessor(s)

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Example 7.3

7/30/2019 Layout Line Balancing

16/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

Figu re 7.12

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

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L ine Balancing Big Broadcaster

Example 7.4

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week

7/30/2019 Layout Line Balancing

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L ine Balancing Big Broadcaster

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week

r= 2400/40 = 60 units/hour

Example 7.4

7/30/2019 Layout Line Balancing

19/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week

r= 2400/40 = 60 units/hour

c= 1/60 = 1 minute/unit

= 60 seconds/unit

Example 7.4

7/30/2019 Layout Line Balancing

20/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unit

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week

Example 7.4

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unit

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week

TM = 244 seconds/60 seconds= 4.067 or 5 stations

Example 7.4

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unit

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week

TM = 244 seconds/60 seconds= 4.067 or 5 stations

Efficiency = [244\5(60)]100 = 81.3%

Example 7.4

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Desired output rate = 2400/week

Plant operates 40 hours/week

TM = 244 seconds/60 seconds= 4.067 or 5 stations

Efficiency = [244\5(60)]100 = 81.3%

Example 7.4

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

S2

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

S2

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

S2

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

S2

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

S2

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30

E,F,G F 55 5

Example 7.5

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S1

S2

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Cumm Idle

Station Candidate Choice Time Time

S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30

E,F,G F 55 5

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1

S2

S3

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30

E,F,G F 55 5

Cumm Idle

Station Candidate Choice Time Time

Example 7.5

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To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

L ine Balancing Big Broadcaster

c= 60 seconds/unitTM = 5 stations

Efficiency = 81.3%

S1 S3

S2

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G

Example 7.5

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L ine Balancing Big Broadcaster

c= 60 seconds/unit

TM = 5 stations

Efficiency = 81.3%

S1

S2

S3

S5S4

Figu re 7.13

40

6

20

50

15

18

E30

25

40H

I

D

B

F

C

A

G