Layout Line Balancing
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Transcript of Layout Line Balancing
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7/30/2019 Layout Line Balancing
1/38
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.
L ine Balancing
Green Grass , Inc .
Big B roadcaster
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7/30/2019 Layout Line Balancing
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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
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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7/30/2019 Layout Line Balancing
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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
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7/30/2019 Layout Line Balancing
5/38
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 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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7/30/2019 Layout Line Balancing
6/38
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
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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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7/30/2019 Layout Line Balancing
17/38To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.
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
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7/30/2019 Layout Line Balancing
18/38To 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
Example 7.4
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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
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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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7/30/2019 Layout Line Balancing
21/38
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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7/30/2019 Layout Line Balancing
22/38
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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7/30/2019 Layout Line Balancing
23/38
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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7/30/2019 Layout Line Balancing
24/38
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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7/30/2019 Layout Line Balancing
25/38
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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26/38
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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27/38
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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28/38
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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29/38
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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30/38
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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31/38
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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7/30/2019 Layout Line Balancing
32/38
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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7/30/2019 Layout Line Balancing
33/38
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
-
7/30/2019 Layout Line Balancing
34/38
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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7/30/2019 Layout Line Balancing
35/38
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.
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
-
7/30/2019 Layout Line Balancing
36/38
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
-
7/30/2019 Layout Line Balancing
37/38
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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38/38
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