Line Balancing

Green Grass, Inc. Big Broadcaster

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

Line Balancing

It is the assignment of Workstations in a production line so as to achieve the desired output rate with the

smallest number of Work- stations

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

Assembly-Line Balancing
Objective is to minimize the imbalance between machines or personnel while meeting required output
Starts with the precedence relationships
1. Determine cycle time
2. Calculate theoretical minimum number of workstations 3. Balance the line by assigning specific tasks to workstations 3

Line Balancing

Big Broadcaster

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

Line Balancing
Work Element A B C D E F G H I Total
Example 7.3

Big Broadcaster

Description
Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

Time (sec) 40 30 50 40 6 25 15 20 18 244

Immediate Predecessor(s) None A A B B C C D, E F, G

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

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

None A A B B C C D, E F, G

Example 7.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

None A A B B C C D, E F, G

40

Example 7.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30

None A A B B C C D, E F, G

40

Example 7.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30

None A A B B C C D, E F, G

40

C 50

Example 7.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30

None A A B B C C D, E F, G

D 40

40

C 50

Example 7.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30

None A A B B C C D, E F, G

D 40
E

40

C 50

Example 7.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30 F 25

None A A B B C C D, E F, G

D 40
E

40

C 50

Example 7.3
To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition 2004 Prentice Hall, Inc. All rights reserved.

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30 F 25

None A A B B C C D, E F, G

D 40
E

40

C 50

G
Example 7.3

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

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30 F 25

None A A B B C C D, E F, G

D 40
E

H 20

40

C 50

G
Example 7.3

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

Line Balancing
Work Element Description Time Immediate (sec) Predecessor(s)

Big Broadcaster

A B C D E F G H I
Total

Bolt leg frame to hopper Insert impeller shaft Attach axle Attach agitator Attach drive wheel Attach free wheel Mount lower post Attach controls Mount nameplate

40 30 50 40 6 25 15 20 18
244

30 F 25

None A A B B C C D, E F, G

D 40
E

H 20

40

C 50

I G
18

Example 7.3

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

Line Balancing
D
B

Big Broadcaster

H 20 E

40 6

30
A

40

C 50

F 25 I G
18

Figure 7.12

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

Line Balancing
D
B

Big Broadcaster

H 20 E

40 6

30
A

40

C 50

F 25

Desired output rate = 2400/week Plant operates 40 hours/week

I G
18

Example 7.4

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

Line Balancing
D
B

Big Broadcaster

H 20 E

40 6

30
A

40

C 50

F 25

Desired output rate = 2400/week Plant operates 40 hours/week r = 2400/40 = 60 Iunits/hour

G
Example 7.4

18

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

Line Balancing
D
B

Big Broadcaster

H 20 E

40 6

30
A

40

C 50

F 25

Desired output rate = 2400/week Plant operates 40 hours/week r = 2400/40 = I60 units/hour

18 1/60 = 1 minute/unit G c= = 60 seconds/unit

Example 7.4

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

Line Balancing
c = 60 seconds/unit

Big Broadcaster

D
B

H 20 E

40 6

30
A

40

C 50

F 25

Desired output rate = 2400/week Plant operates 40 hours/week

I G
18

Example 7.4

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

Line Balancing
c = 60 seconds/unit

Big Broadcaster

D
B

H 20 E

40 6

30
A

40

C 50

F 25

Desired output rate = 2400/week Plant operates 40 hours/week TM = 244 seconds/60 seconds I = 4.067 or 5 stations

G
Example 7.4

18

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

Line Balancing
c = 60 seconds/unit

Big Broadcaster

D
B

H 20 E

40 6

30
A

40

C 50

F 25

Desired output rate = 2400/week Plant operates 40 hours/week TM = 244 seconds/60 seconds I = 4.067 or 5 stations

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

Example 7.4

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

30
A

40

C 50

F 25

Desired output rate = 2400/week Plant operates 40 hours/week TM = 244 seconds/60 seconds I = 4.067 or 5 stations

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

Example 7.4

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

30
A

40

C 50

F 25

Cumm Station Candidate Choice Time

Idle Time

I G
18

Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

30
A

40

C 50

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

I G
18

Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

30
A

40

C 50

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

I G
18

Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 F 25

40

Cumm Station Candidate Choice Time

Idle Time

C 50

S1

40

20

I G
18

Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 F 25

40

Cumm Station Candidate Choice Time

Idle Time

C 50

S1

40

20

S2

B,C

C I

50

10

G
Example 7.5

18

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 F 25

40

Cumm Station Candidate Choice Time

Idle Time

C 50

S1

40

20

S2

B,C

C I

50

10

G
Example 7.5

18

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S2
C 50

40

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

S2

B,C

C I

50

10

G
Example 7.5

18

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S2
C 50

40

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

S2
S3

B,C
B,F,G

C I

50
30

10
30

G
Example 7.5

18

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S2
C 50

40

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

S2
S3

B,C
B,F,G

C I

50
30

10
30

G
Example 7.5

18

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S2
C 50

40

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

S2
S3

B,C
B,F,G

C I

50
30

10
30

G
Example 7.5

18

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S2
C 50

40

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

S2
S3

B,C
B,F,G E,F,G

C I
B 18 F

50
30 55

10
30 5

G
Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S2
C 50

40

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

S2
S3

B,C
B,F,G E,F,G

C I
B 18 F

50
30 55

10
30 5

G
Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S3 S2
C 50

40

F 25

Cumm Station Candidate Choice Time

Idle Time

S1

40

20

S2
S3

B,C
B,F,G E,F,G

C I
B 18 F

50
30 55

10
30 5

G
Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6

S1 A

30 S3 S2
C 50

40

F 25 I G
18

Example 7.5

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

Line Balancing
c = 60 seconds/unit TM = 5 stations Efficiency = 81.3%

Big Broadcaster

D
B

H 20 E

40 6 S5

S1 A

30 S3 S2
C 50

S4

40

F 25

I G
18

Figure 7.13

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